Technogym BIOSTRENGTH LINE Service Maintenance Manual

ERVICE & MAINTENANCE MANUAL

S

REV. 2.1

The information contained in this manual is intended for QUALIFIED TECHNICIANS who have
completed a specific TECHNOGYM training course and are authorized to perform machine start-up
and adjustment procedures as well as extraordinary maintenance or repairs which require a thorough

knowledge of the machine, its operation, its safety devices and working procedures.

CAREFULLY READ THE INFORMATION CONTAINED IN THIS MANUAL BEFORE

PERFORMING ANY MAINTENANCE PROCEDURES ON THE MACHINE

DANGEROUS VOLTAGES

PRESENT EVEN WHEN THE

NOTE

The information contained in this document is subject to change without notice.

Technogym does not guarantee this documentation in any way. Technogym shall not be held
responsible for any errors contained in this manual and declines all liability for accidents or
damages resulting from the supply, characteristics and use of this manual.

This document contains proprietary information that is protected by copyright. All rights reserved.
No part of this document may be photocopied, reproduced or translated into another language
without the prior written consent of Technogym.

The Technogym™ trademark is property of Technogym S.p.A.
The Biostrength™ trademark is property of Technogym S.p.A.

MACHINE IS TURNED OFF

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

Contents

1. GENERAL NOTICES............................................................................................................................................1.1

1.1. INTRODUCTION .................................................................................................................................................1.1

1.2. RECOMMENDATIONS.........................................................................................................................................1.1

1.3. GENERAL RULES FOR REPAIR PROCEDURES....................................................................................................... 1.2

2. TECHNICAL SPECIFICATIONS .......................................................................................................................2.1

2.1. MECHANICAL CHARACTERISTICS ......................................................................................................................2.1

2.1.1. Abdominal Crunch................................................................................................................................2.1

2.1.2. Lower Back...........................................................................................................................................2.1

2.1.3. Leg Extension .......................................................................................................................................2.2

2.1.4. Leg Curl................................................................................................................................................2.2

2.1.5. Vertical Traction...................................................................................................................................2.2

2.1.6. Shoulder Press......................................................................................................................................2.3

2.1.7. Chest Press ...........................................................................................................................................2.3

2.1.8. Rowing Torso........................................................................................................................................2.3

2.1.9. Leg Press ..............................................................................................................................................2.4

2.2. ELECTRICAL CHARACTERISTICS ........................................................................................................................2.4

2.3. AMBIENT SPECIFICATIONS.................................................................................................................................2.5

2.4. CONFORMITY TO REGULATIONS ........................................................................................................................2.5

2.5. UNIFIED BOARD VERSION.................................................................................................................................. 2.6

2.5.1. Type A wiring diagram.........................................................................................................................2.6

2.5.2. Type B wiring diagram.......................................................................................................................2.12

2.5.3. Type C wiring diagram.......................................................................................................................2.19

2.5.4. Type D wiring diagram.......................................................................................................................2.26

2.6. SEPARATED BOARD VERSION ..........................................................................................................................2.34

2.6.1. Type A wiring diagram.......................................................................................................................2.34

2.6.2. Type B wiring diagram.......................................................................................................................2.41

2.6.3. Type C wiring diagram.......................................................................................................................2.50

2.6.4. Type D wiring diagram.......................................................................................................................2.59

3. OPERATING PRINCIPLE ...................................................................................................................................3.1

3.1. BLOCK DIAGRAM ..............................................................................................................................................3.1

3.1.1. Power Entry..........................................................................................................................................3.2

3.1.2. Power Switch........................................................................................................................................3.2

3.1.3. Fuses.....................................................................................................................................................3.2

3.1.4. Filter.....................................................................................................................................................3.2

3.1.5. Voltage selector board..........................................................................................................................3.2

3.1.6. Power supply ........................................................................................................................................3.2

3.1.7. Transformer..........................................................................................................................................3.2

3.1.8. Display..................................................................................................................................................3.3

3.1.9. Bio Servo Board....................................................................................................................................3.3

3.1.10. LP driver board ....................................................................................................................................3.4

3.1.11. Wire encoder.........................................................................................................................................3.5

3.1.12. Solenoid ................................................................................................................................................3.5

3.1.13. Weight stack motor ...............................................................................................................................3.5

3.1.14. Seat motor.............................................................................................................................................3.5

3.1.15. LP seat motor........................................................................................................................................3.6

3.1.16. Zero sensor ...........................................................................................................................................3.6

3.1.17. Safety device .........................................................................................................................................3.6

3.2. SOLENOID MANAGEMENT..................................................................................................................................3.8

3.2.1. Mechanics.............................................................................................................................................3.8

3.2.2. Controls ................................................................................................................................................3.8

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3.2.3. The signals involved .............................................................................................................................3.9

3.3. WEIGHT STACK MOTOR MANAGEMENT ...........................................................................................................3.12

3.3.1. Mechanics...........................................................................................................................................3.12

3.3.2. Controls ..............................................................................................................................................3.13

3.3.3. The signals involved ...........................................................................................................................3.14

3.4. SEAT MOTOR MANAGEMENT ...........................................................................................................................3.18

3.4.1. Mechanics...........................................................................................................................................3.18

3.4.2. Controls ..............................................................................................................................................3.18

3.4.3. The signals involved ...........................................................................................................................3.20

3.5. SEAT MOTOR MANAGEMENT FOR LEG PRESS ..................................................................................................3.24

3.5.1. Mechanics...........................................................................................................................................3.24

3.5.2. Controls ..............................................................................................................................................3.24

3.5.3. The signals involved ...........................................................................................................................3.26

3.6. WIRE ENCODER MANAGEMENT .......................................................................................................................3.30

3.6.1. Mechanics...........................................................................................................................................3.30

3.6.2. Controls ..............................................................................................................................................3.30

3.6.3. The signals involved ...........................................................................................................................3.30

4. ACCESSORIES ...................................................................................................................................................... 4.1

5. INSTALLATION INSTRUCTIONS ....................................................................................................................5.1

5.1. SPECIFICATIONS AND REQUIREMENTS ...............................................................................................................5.1

5.2. INSTALLATION ..................................................................................................................................................5.1

5.3. FIRST POWER-ON...............................................................................................................................................5.1

6. TROUBLESHOOTING.........................................................................................................................................6.1

6.1. MANUAL COMPONENTS TEST ...........................................................................................................................6.2

6.1.1. Weight stack motor ...............................................................................................................................6.2

6.1.2. Zero sensor status.................................................................................................................................6.3

6.1.3. Seat motor.............................................................................................................................................6.4

6.1.4. Solenoid ................................................................................................................................................6.5

6.2. AUTOMATIC COMPONENTS TEST .......................................................................................................................6.7

6.2.1. Monitoring communication between the Bio servo board and the CPU board....................................6.7

6.2.2. Counter display.....................................................................................................................................6.8

6.3. RESET PROCEDURE ...........................................................................................................................................6.9

6.3.1. Buffer battery test .................................................................................................................................6.9

6.3.2. TGS interface test .................................................................................................................................6.9

6.3.3. FPGA test .............................................................................................................................................6.9

6.3.4. Solenoid test........................................................................................................................................6.10

6.3.5. Weight stack motor test.......................................................................................................................6.10

6.3.6. Seat motor test .................................................................................................................................... 6.12

6.4. TEST PROCEDURE DURING USE........................................................................................................................6.14

6.4.1. Weight stack motor failure.................................................................................................................. 6.14

6.4.2. Seat motor test .................................................................................................................................... 6.14

6.5. THE LCD DISPLAYS THE MESSAGE “HW FAULT: CHECK BATTERY” ...............................................................6.16

6.6. THE LCD DISPLAYS THE MESSAGE “HW FAULT: CHECK TGS” ......................................................................6.17

6.7. THE LCD DISPLAYS THE MESSAGE “HW FAULT: CHECK FPGA”....................................................................6.19

6.8. THE LCD DISPLAYS THE MESSAGE “ADD-ON WEIGHT PROBLEM = MAGNET”..................................................6.20

6.9. THE LCD DISPLAYS THE MESSAGE “WEIGHT STACK PROBLEM = FAIL” ..........................................................6.24

6.10. THE LCD DISPLAYS THE MESSAGE “WEIGHT STACK PROBLEM = MOTOR”......................................................6.25

6.11. THE LCD DISPLAYS THE MESSAGE “WEIGHT STACK PROBLEM = ENCODER” ..................................................6.28

6.12. THE LCD DISPLAYS THE MESSAGE “WEIGHT STACK PROBLEM = LIMIT SWITCH SENSOR”...............................6.30

6.13. THE LCD DISPLAYS THE MESSAGE “SEAT PROBLEM = FAIL” ..........................................................................6.32

6.14. THE LCD DISPLAYS THE MESSAGE “EMERGENCY ACTIVATED” ...................................................................... 6.33

6.15. THE LCD DISPLAYS THE MESSAGE “SEAT PROBLEM = MOTOR”......................................................................6.35

6.15.1. For Leg Press .....................................................................................................................................6.35

6.15.2. For Leg Extension, Leg Curl, Vertical Traction, Shoulder Press, Chest Press and Rowing Torso....6.38

6.16. THE LCD DISPLAYS THE MESSAGE “SEAT PROBLEM = ENCODER” ..................................................................6.40

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6.16.1. For Leg Press .....................................................................................................................................6.40

6.16.2. For Leg Extension, Leg Curl, Vertical Traction, Shoulder Press, Chest Press and Rowing Torso....6.43

6.17. THE DISPLAY DOES NOT TURN ON ...................................................................................................................6.45

6.18. THE MACHINE DOES NOT READ THE TGS: THE RED LED ON THE KEY READER IS NOT LIT ..............................6.50

7. DISASSEMBLY OF COMPONENTS .................................................................................................................7.1

7.1. ABDOMINAL CRUNCH .......................................................................................................................................7.1

7.1.1. Disassembling the display ....................................................................................................................7.1

7.1.2. Removing the electronic display boards...............................................................................................7.2

7.1.3. Removing the EPROM..........................................................................................................................7.4

7.1.4. Disassembling the TLCBR chip............................................................................................................7.5

7.1.5. Disassembling the main keyboard ........................................................................................................7.6

7.1.6. Disassembling the plexiglas weight stack guard ..................................................................................7.7

7.1.7. Disassembling the weight stack pulleys................................................................................................7.8

7.1.8. Disassembling the weight stack cover .................................................................................................. 7.9

7.1.9. Disassembling the additional weight..................................................................................................7.11

7.1.10. Disassembling the encoder.................................................................................................................7.12

7.1.11. Disassembling the solenoid ................................................................................................................7.13

7.1.12. Disassembling the selector brush .......................................................................................................7.14

7.1.13. Disassembling the zero sensor............................................................................................................7.15

7.1.14. Disassembling the weight stack selection system................................................................................7.16

7.1.15. Disassembling the weight stack selection chain .................................................................................7.17

7.1.16. Disassembling the weight stack motor................................................................................................7.18

7.1.17. Disassembling the cross stops ............................................................................................................7.19

7.1.18. Disassembling the cross......................................................................................................................7.20

7.1.19. Disassembling the sinker .................................................................................................................... 7.21

7.1.20. Disassembling the weight stack plates................................................................................................7.22

7.1.21. Disassembling the bars.......................................................................................................................7.23

7.1.22. Disassembling the seat guard............................................................................................................. 7.24

7.1.23. Disassembling the electrical box ........................................................................................................7.25

7.1.24. Disassembling the electronic components of the electrical box .........................................................7.26

7.1.25. Disassembling the bell guard .............................................................................................................7.28

7.1.26. Disassembling the weight stack frame guard .....................................................................................7.29

7.1.27. Disassembling the weight stack cable.................................................................................................7.30

7.1.28. Disassembling the bell........................................................................................................................7.31

7.1.29. Disassembling the primary shaft - secondary shaft chain .................................................................. 7.32

7.1.30. Disassembling the primary shaft ........................................................................................................7.33

7.1.31. Disassembling the secondary shaft.....................................................................................................7.35

7.1.32. Disassembling the weight stack frame pulley .....................................................................................7.37

7.1.33. Disassembling the mat........................................................................................................................7.38

7.1.34. Disassembling the power entry...........................................................................................................7.39

7.1.35. Disassembling the starter plate and fuses ..........................................................................................7.40

7.2. LOWER BACK..................................................................................................................................................7.41

7.2.1. Disassembling the display ..................................................................................................................7.41

7.2.2. Removing the electronic display boards.............................................................................................7.42

7.2.3. Removing the EPROM........................................................................................................................7.44

7.2.4. Disassembling the TLCBR chip..........................................................................................................7.45

7.2.5. Disassembling the main keyboard ......................................................................................................7.46

7.2.6. Disassembling the plexiglas weight stack guard ................................................................................7.47

7.2.7. Disassembling the weight stack pulleys..............................................................................................7.48

7.2.8. Disassembling the weight stack cover ................................................................................................ 7.49

7.2.9. Disassembling the additional weight..................................................................................................7.51

7.2.10. Disassembling the encoder.................................................................................................................7.52

7.2.11. Disassembling the solenoid ................................................................................................................7.53

7.2.12. Disassembling the selector brush .......................................................................................................7.54

7.2.13. Disassembling the zero sensor............................................................................................................7.55

7.2.14. Disassembling the weight stack selection system................................................................................7.56

7.2.15. Disassembling the weight stack selection chain .................................................................................7.57

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7.2.16. Disassembling the weight stack motor................................................................................................7.58

7.2.17. Disassembling the cross stops ............................................................................................................7.59

7.2.18. Disassembling the cross......................................................................................................................7.60

7.2.19. Disassembling the sinker .................................................................................................................... 7.61

7.2.20. Disassembling the weight stack plates................................................................................................7.62

7.2.21. Disassembling the bars.......................................................................................................................7.63

7.2.22. Disassembling the seat guard............................................................................................................. 7.64

7.2.23. Disassembling the electrical box ........................................................................................................7.65

7.2.24. Disassembling the electronic components of the electrical box .........................................................7.66

7.2.25. Disassembling the bell guard .............................................................................................................7.68

7.2.26. Disassembling the weight stack frame guard .....................................................................................7.69

7.2.27. Disassembling the weight stack cable.................................................................................................7.70

7.2.28. Disassembling the release lever cable................................................................................................7.71

7.2.29. Disassembling the bell........................................................................................................................7.73

7.2.30. Disassembling the primary shaft - secondary shaft chain .................................................................. 7.74

7.2.31. Disassembling the primary shaft ........................................................................................................7.75

7.2.32. Disassembling the secondary shaft.....................................................................................................7.77

7.2.33. Disassembling the weight stack frame pulley .....................................................................................7.79

7.2.34. Disassembling the mat........................................................................................................................7.80

7.2.35. Disassembling the power entry...........................................................................................................7.81

7.2.36. Disassembling the starter plate and fuses ..........................................................................................7.82

7.3. LEG EXTENSION..............................................................................................................................................7.83

7.3.1. Disassembling the display ..................................................................................................................7.83

7.3.2. Removing the electronic display boards.............................................................................................7.84

7.3.3. Removing the EPROM........................................................................................................................7.86

7.3.4. Disassembling the TLCBR chip..........................................................................................................7.87

7.3.5. Disassembling the main keyboard ......................................................................................................7.88

7.3.6. Disassembling the seat keyboard........................................................................................................7.89

7.3.7. Disassembling the Plexiglas weight stack guard................................................................................ 7.90

7.3.8. Disassembling the weight stack pulleys..............................................................................................7.91

7.3.9. Disassembling the weight stack cover ................................................................................................ 7.92

7.3.10. Disassembling the additional weight..................................................................................................7.94

7.3.11. Disassembling the encoder.................................................................................................................7.95

7.3.12. Disassembling the solenoid ................................................................................................................7.96

7.3.13. Disassembling the selector brush .......................................................................................................7.97

7.3.14. Disassembling the zero sensor............................................................................................................7.98

7.3.15. Disassembling the weight stack selection system................................................................................7.99

7.3.16. Disassembling the weight stack selection chain ...............................................................................7.100

7.3.17. Disassembling the weight stack motor..............................................................................................7.101

7.3.18. Disassembling the cross stops ..........................................................................................................7.102

7.3.19. Disassembling the cross....................................................................................................................7.103

7.3.20. Disassembling the sinker .................................................................................................................. 7.104

7.3.21. Disassembling the weight stack plates..............................................................................................7.105

7.3.22. Disassembling the bars.....................................................................................................................7.106

7.3.23. Disassembling the seat guard........................................................................................................... 7.107

7.3.24. Disassembling the seat motor...........................................................................................................7.108

7.3.25. Disassembling the electrical box ......................................................................................................7.110

7.3.26. Disassembling the electronic components of the electrical box .......................................................7.111

7.3.27. Disassembling the bell guard ...........................................................................................................7.113

7.3.28. Disassembling the weight stack frame guard ...................................................................................7.114

7.3.29. Disassembling the weight stack cable...............................................................................................7.115

7.3.30. Disassembling the bell......................................................................................................................7.116

7.3.31. Disassembling the primary shaft - secondary shaft chain ................................................................ 7.117

7.3.32. Disassembling the primary shaft ......................................................................................................7.118

7.3.33. Disassembling the secondary shaft...................................................................................................7.120

7.3.34. Disassembling the weight stack frame pulley ...................................................................................7.122

7.3.35. Disassembling the mat......................................................................................................................7.123

7.3.36. Disassembling the power entry.........................................................................................................7.124

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7.3.37. Disassembling the starter plate and fuses ........................................................................................7.125

7.4. LEG CURL .....................................................................................................................................................7.126

7.4.1. Disassembling the display ................................................................................................................7.126

7.4.2. Removing the electronic display boards...........................................................................................7.127

7.4.3. Removing the EPROM......................................................................................................................7.129

7.4.4. Disassembling the TLCBR chip........................................................................................................7.130

7.4.5. Disassembling the main keyboard ....................................................................................................7.131

7.4.6. Disassembling the seat keyboard......................................................................................................7.132

7.4.7. Disassembling the plexiglas weight stack guard ..............................................................................7.133

7.4.8. Disassembling the weight stack pulleys............................................................................................7.134

7.4.9. Disassembling the weight stack cover .............................................................................................. 7.135

7.4.10. Disassembling the additional weight................................................................................................7.137

7.4.11. Disassembling the encoder...............................................................................................................7.138

7.4.12. Disassembling the solenoid ..............................................................................................................7.139

7.4.13. Disassembling the selector brush .....................................................................................................7.140

7.4.14. Disassembling the zero sensor..........................................................................................................7.141

7.4.15. Disassembling the weight stack selection system..............................................................................7.142

7.4.16. Disassembling the weight stack selection chain ...............................................................................7.143

7.4.17. Disassembling the weight stack motor..............................................................................................7.144

7.4.18. Disassembling the cross stops ..........................................................................................................7.145

7.4.19. Disassembling the cross....................................................................................................................7.146

7.4.20. Disassembling the sinker .................................................................................................................. 7.147

7.4.21. Disassembling the weight stack plates..............................................................................................7.148

7.4.22. Disassembling the bars.....................................................................................................................7.149

7.4.23. Disassembling the seat guard........................................................................................................... 7.150

7.4.24. Disassembling the seat motor...........................................................................................................7.151

7.4.25. Disassembling the electrical box ......................................................................................................7.153

7.4.26. Disassembling the electronic components of the electrical box .......................................................7.154

7.4.27. Disassembling the bell guard ...........................................................................................................7.156

7.4.28. Disassembling the weight stack frame guard ...................................................................................7.157

7.4.29. Disassembling the weight stack cable...............................................................................................7.158

7.4.30. Disassembling the bell......................................................................................................................7.159

7.4.31. Disassembling the primary shaft - secondary shaft chain ................................................................ 7.160

7.4.32. Disassembling the primary shaft ......................................................................................................7.161

7.4.33. Disassembling the secondary shaft...................................................................................................7.163

7.4.34. Disassembling the weight stack frame pulley ...................................................................................7.165

7.4.35. Disassembling the mat......................................................................................................................7.166

7.4.36. Disassembling the power entry.........................................................................................................7.167

7.4.37. Disassembling the starter plate and fuses ........................................................................................7.168

7.5. VERTICAL TRACTION..................................................................................................................................... 7.169

7.5.1. Disassembling the display ................................................................................................................7.169

7.5.2. Removing the electronic display boards...........................................................................................7.170

7.5.3. Removing the EPROM......................................................................................................................7.172

7.5.4. Disassembling the TLCBR chip........................................................................................................7.173

7.5.5. Disassembling the main keyboard ....................................................................................................7.174

7.5.6. Disassembling the seat keyboard......................................................................................................7.175

7.5.7. Removing the seat.............................................................................................................................7.176

7.5.8. Disassembling the front guard..........................................................................................................7.177

7.5.9. Disassembling the electrical box......................................................................................................7.178

7.5.10. Disassembling the electronic components of the electrical box .......................................................7.179

7.5.11. Disassembling the upright guard......................................................................................................7.181

7.5.12. Disassembling the seat motor...........................................................................................................7.182

7.5.13. Disassembling the prestart cable......................................................................................................7.183

7.5.14. Disassembling the rear guard...........................................................................................................7.185

7.5.15. Disassembling the solenoid ..............................................................................................................7.186

7.5.16. Disassembling the selector brush .....................................................................................................7.187

7.5.17. Disassembling the weight stack cable...............................................................................................7.188

7.5.18. Disassembling the pulleys.................................................................................................................7.189

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7.5.19. Disassembling the zero sensor..........................................................................................................7.190

7.5.20. Disassembling the weight stack selection system..............................................................................7.191

7.5.21. Disassembling the weight stack selection chain ...............................................................................7.193

7.5.22. Disassembling the weight stack motor..............................................................................................7.194

7.5.23. Disassembling the rear lever guard..................................................................................................7.195

7.5.24. Disassembling the lever cable ..........................................................................................................7.196

7.5.25. Disassembling the cam group...........................................................................................................7.197

7.5.26. Disassembling the levers ..................................................................................................................7.198

7.5.27. Disassembling the front lever guard.................................................................................................7.199

7.5.28. Disassembling the weight stack cover ..............................................................................................7.200

7.5.29. Disassembling the column extension ................................................................................................7.201

7.5.30. Disassembling the columns...............................................................................................................7.202

7.5.31. Disassembling the additional weight................................................................................................7.203

7.5.32. Disassembling the encoder...............................................................................................................7.204

7.5.33. Disassembling the bars.....................................................................................................................7.205

7.5.34. Disassembling the cross and weight stack plates .............................................................................7.206

7.5.35. Disassembling the sinker .................................................................................................................. 7.207

7.5.36. Disassembling the mats ....................................................................................................................7.208

7.5.37. Disassembling the display support ...................................................................................................7.209

7.5.38. Disassembling the power entry.........................................................................................................7.210

7.5.39. Disassembling the starter plate and fuses ........................................................................................7.211

7.6. SHOULDER PRESS .........................................................................................................................................7.212

7.6.1. Disassembling the display ................................................................................................................7.212

7.6.2. Removing the electronic display boards...........................................................................................7.213

7.6.3. Removing the EPROM......................................................................................................................7.215

7.6.4. Disassembling the TLCBR chip........................................................................................................7.216

7.6.5. Disassembling the main keyboard....................................................................................................7.217

7.6.6. Disassembling the seat keyboard......................................................................................................7.218

7.6.7. Removing the seat.............................................................................................................................7.219

7.6.8. Disassembling the front guard..........................................................................................................7.220

7.6.9. Disassembling the electrical box......................................................................................................7.221

7.6.10. Disassembling the electronic components of the electrical box .......................................................7.222

7.6.11. Disassembling the upright guard......................................................................................................7.224

7.6.12. Disassembling the seat motor...........................................................................................................7.225

7.6.13. Disassembling the prestart cable......................................................................................................7.226

7.6.14. Disassembling the rear guard...........................................................................................................7.228

7.6.15. Disassembling the solenoid ..............................................................................................................7.229

7.6.16. Disassembling the selector brush .....................................................................................................7.230

7.6.17. Disassembling the weight stack cable...............................................................................................7.231

7.6.18. Disassembling the pulleys.................................................................................................................7.232

7.6.19. Disassembling the zero sensor..........................................................................................................7.233

7.6.20. Disassembling the weight stack selection system..............................................................................7.234

7.6.21. Disassembling the weight stack selection chain ...............................................................................7.236

7.6.22. Disassembling the weight stack motor..............................................................................................7.237

7.6.23. Disassembling the rear lever guard..................................................................................................7.238

7.6.24. Disassembling the lever cable ..........................................................................................................7.239

7.6.25. Disassembling the cam group...........................................................................................................7.240

7.6.26. Disassembling the levers ..................................................................................................................7.241

7.6.27. Disassembling the front lever guard.................................................................................................7.242

7.6.28. Disassembling the weight stack cover ..............................................................................................7.243

7.6.29. Disassembling the column extension ................................................................................................7.244

7.6.30. Disassembling the columns...............................................................................................................7.245

7.6.31. Disassembling the additional weight................................................................................................7.246

7.6.32. Disassembling the encoder...............................................................................................................7.247

7.6.33. Disassembling the bars.....................................................................................................................7.248

7.6.34. Disassembling the cross and weight stack plates .............................................................................7.249

7.6.35. Disassembling the sinker .................................................................................................................. 7.250

7.6.36. Disassembling the mats ....................................................................................................................7.251

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7.6.37. Disassembling the display support ...................................................................................................7.252

7.6.38. Disassembling the power entry.........................................................................................................7.253

7.6.39. Disassembling the starter plate and fuses ........................................................................................7.254

7.7. CHEST PRESS ................................................................................................................................................7.255

7.7.1. Disassembling the display ................................................................................................................7.255

7.7.2. Removing the electronic display boards...........................................................................................7.256

7.7.3. Removing the EPROM......................................................................................................................7.258

7.7.4. Disassembling the TLCBR chip........................................................................................................7.259

7.7.5. Disassembling the main keyboard ....................................................................................................7.260

7.7.6. Disassembling the seat keyboard......................................................................................................7.261

7.7.7. Disassembling the rear Plexiglas weight stack guard......................................................................7.262

7.7.8. Disassembling the front plexiglas weight stack guard......................................................................7.263

7.7.9. Disassembling the weight stack pulley .............................................................................................7.264

7.7.10. Disassembling the weight stack cover ..............................................................................................7.265

7.7.11. Disassembling the additional weight................................................................................................7.267

7.7.12. Disassembling the encoder...............................................................................................................7.268

7.7.13. Disassembling the solenoid ..............................................................................................................7.269

7.7.14. Disassembling the selector brush .....................................................................................................7.270

7.7.15. Disassembling the zero sensor..........................................................................................................7.271

7.7.16. Removing the seat.............................................................................................................................7.272

7.7.17. Disassembling the upright guard......................................................................................................7.273

7.7.18. Disassembling the closing panels..................................................................................................... 7.274

7.7.19. Disassembling the weight stack selection system..............................................................................7.275

7.7.20. Disassembling the weight stack selection chain ...............................................................................7.276

7.7.21. Disassembling the weight stack motor..............................................................................................7.277

7.7.22. Disassembling the cross stops ..........................................................................................................7.278

7.7.23. Disassembling the cross....................................................................................................................7.279

7.7.24. Disassembling the sinker .................................................................................................................. 7.280

7.7.25. Disassembling the weight stack plates..............................................................................................7.281

7.7.26. Disassembling the bars.....................................................................................................................7.282

7.7.27. Disassembling the seat motor...........................................................................................................7.283

7.7.28. Disassembling the electrical box ......................................................................................................7.284

7.7.29. Disassembling the electronic components of the electrical box .......................................................7.285

7.7.30. Disassembling the pulleys.................................................................................................................7.287

7.7.31. Disassembling the weight stack cable...............................................................................................7.288

7.7.32. Disassembling the lever cable ..........................................................................................................7.289

7.7.33. Disassembling the doubling cable....................................................................................................7.290

7.7.34. Disassembling the cam group...........................................................................................................7.291

7.7.35. Disassembling the front guard..........................................................................................................7.292

7.7.36. Disassembling the prestart cable......................................................................................................7.293

7.7.37. Disassembling the levers ..................................................................................................................7.295

7.7.38. Disassembling the mats ....................................................................................................................7.296

7.7.39. Disassembling the display support ...................................................................................................7.297

7.7.40. Disassembling the power entry.........................................................................................................7.298

7.7.41. Disassembling the starter plate and fuses ........................................................................................7.299

7.8. ROWING TORSO ............................................................................................................................................7.300

7.8.1. Disassembling the display ................................................................................................................7.300

7.8.2. Removing the electronic display boards...........................................................................................7.301

7.8.3. Removing the EPROM......................................................................................................................7.303

7.8.4. Disassembling the TLCBR chip........................................................................................................7.304

7.8.5. Disassembling the main keyboard ....................................................................................................7.305

7.8.6. Disassembling the seat keyboard......................................................................................................7.306

7.8.7. Disassembling the rear plexiglas weight stack guard ......................................................................7.307

7.8.8. Disassembling the front plexiglas weight stack guard......................................................................7.308

7.8.9. Disassembling the weight stack pulley .............................................................................................7.309

7.8.10. Disassembling the weight stack cover ..............................................................................................7.310

7.8.11. Disassembling the additional weight................................................................................................7.312

7.8.12. Disassembling the encoder...............................................................................................................7.313

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7.8.13. Disassembling the solenoid ..............................................................................................................7.314

7.8.14. Disassembling the selector brush .....................................................................................................7.315

7.8.15. Disassembling the zero sensor..........................................................................................................7.316

7.8.16. Disassembling the mats ....................................................................................................................7.317

7.8.17. Disassembling the prestart levers.....................................................................................................7.318

7.8.18. Disassembling the upright guard......................................................................................................7.319

7.8.19. Disassembling the weight stack selection system..............................................................................7.321

7.8.20. Disassembling the weight stack selection chain ...............................................................................7.322

7.8.21. Disassembling the weight stack motor..............................................................................................7.323

7.8.22. Disassembling the cross stops ..........................................................................................................7.324

7.8.23. Disassembling the cross....................................................................................................................7.325

7.8.24. Disassembling the sinker .................................................................................................................. 7.326

7.8.25. Disassembling the weight stack plates..............................................................................................7.327

7.8.26. Disassembling the bars.....................................................................................................................7.328

7.8.27. Disassembling the electrical box ......................................................................................................7.329

7.8.28. Disassembling the electronic components of the electrical box .......................................................7.330

7.8.29. Disassembling the pulleys.................................................................................................................7.332

7.8.30. Disassembling the weight stack cable...............................................................................................7.333

7.8.31. Disassembling the doubling cable....................................................................................................7.334

7.8.32. Disassembling the cam group...........................................................................................................7.335

7.8.33. Disassembling the levers ..................................................................................................................7.336

7.8.34. Disassembling the chest rest release knob........................................................................................7.337

7.8.35. Disassembling the lever guard .........................................................................................................7.338

7.8.36. Disassembling the lever cable ..........................................................................................................7.339

7.8.37. Disassembling the lever shaft ...........................................................................................................7.340

7.8.38. Disassembling the seat guard........................................................................................................... 7.341

7.8.39. Disassembling the seat motor...........................................................................................................7.342

7.8.40. Disassembling the power entry.........................................................................................................7.343

7.8.41. Disassembling the starter plate and fuses ........................................................................................7.344

7.9. LEG PRESS ....................................................................................................................................................7.345

7.9.1. Disassembling the display ................................................................................................................7.345

7.9.2. Removing the electronic display boards...........................................................................................7.347

7.9.3. Removing the EPROM......................................................................................................................7.349

7.9.4. Disassembling the TLCBR chip........................................................................................................7.350

7.9.5. Disassembling the main keyboard ....................................................................................................7.351

7.9.6. Disassembling the seat keyboard......................................................................................................7.352

7.9.7. Disassembling the weight stack cover .............................................................................................. 7.353

7.9.8. Disassembling the plexiglas weight stack guard ..............................................................................7.354

7.9.9. Disassembling the weight stack pulleys............................................................................................7.355

7.9.10. Disassembling the encoder...............................................................................................................7.356

7.9.11. Disassembling the weight stack cover frame....................................................................................7.357

7.9.12. Disassembling the additional weight................................................................................................7.358

7.9.13. Disassembling the solenoid ..............................................................................................................7.359

7.9.14. Disassembling the selector brush .....................................................................................................7.360

7.9.15. Disassembling the zero sensor..........................................................................................................7.361

7.9.16. Disassembling the weight stack selection system..............................................................................7.362

7.9.17. Disassembling the weight stack selection chain ...............................................................................7.363

7.9.18. Disassembling the weight stack motor..............................................................................................7.364

7.9.19. Disassembling the cross stops ..........................................................................................................7.365

7.9.20. Disassembling the cross....................................................................................................................7.366

7.9.21. Disassembling the sinker .................................................................................................................. 7.367

7.9.22. Disassembling the weight stack plates..............................................................................................7.368

7.9.23. Disassembling the bars.....................................................................................................................7.369

7.9.24. Disassembling the rear guard...........................................................................................................7.370

7.9.25. Disassembling the central guard......................................................................................................7.371

7.9.26. Disassembling the main electrical box ............................................................................................. 7.372

7.9.27. Disassembling the electronic components of the main electrical box ..............................................7.373

7.9.28. Disassembling the secondary electrical box.....................................................................................7.375

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7.9.29. Disassembling the electronic components of the secondary electrical box......................................7.376

7.9.30. Disassembling the seat motor photocell...........................................................................................7.377

7.9.31. Disassembling the seat motor brushes..............................................................................................7.378

7.9.32. Disassembling the seat movement limitation microswitch................................................................7.379

7.9.33. Disassembling the seat motor unit....................................................................................................7.380

7.9.34. Removing the seat.............................................................................................................................7.382

7.9.35. Disassembling the seat sliding bars..................................................................................................7.383

7.9.36. Disassembling the shoulder rest group release cable ......................................................................7.384

7.9.37. Disassembling the shoulder rest group.............................................................................................7.386

7.9.38. Disassembling the tachogenerator guard.........................................................................................7.388

7.9.39. Disassembling the front guard..........................................................................................................7.389

7.9.40. Disassembling the lever mat rubber ................................................................................................. 7.390

7.9.41. Disassembling the levers ..................................................................................................................7.391

7.9.42. Disassembling the lever cable ..........................................................................................................7.392

7.9.43. Disassembling the weight stack frame guard ...................................................................................7.393

7.9.44. Disassembling the weight stack cable...............................................................................................7.394

7.9.45. Disassembling the doubling cable....................................................................................................7.395

7.9.46. Disassembling the cam group...........................................................................................................7.396

7.9.47. Disassembling the weight stack frame pulleys..................................................................................7.397

7.9.48. Disassembling the starter plate and fuses ........................................................................................7.398

7.9.49. Disassembling the mat......................................................................................................................7.399

7.9.50. Disassembling the power entry.........................................................................................................7.400

8. ADJUSTMENTS ....................................................................................................................................................8.1

8.1. ADJUSTING THE WEIGHT STACK PLATE SELECTION............................................................................................8.1

8.1.1. OFFSET................................................................................................................................................8.1

8.1.2. Distance between plates .......................................................................................................................8.2

8.1.3. Weight stack motor inertia.................................................................................................................... 8.3

8.2. ADJUSTING THE MECHANISMS PHASING ............................................................................................................8.4

8.2.1. Abdominal Crunch................................................................................................................................8.4

8.2.2. Lower Back...........................................................................................................................................8.6

8.2.3. Leg Extension .......................................................................................................................................8.8

8.2.4. Leg Curl..............................................................................................................................................8.10

8.2.5. Vertical Traction.................................................................................................................................8.12

8.2.6. Shoulder Press....................................................................................................................................8.13

8.2.7. Chest Press .........................................................................................................................................8.14

8.2.8. Rowing Torso......................................................................................................................................8.17

8.2.9. Leg Press ............................................................................................................................................8.19

8.3. ADJUSTING THE POSITION OF THE CROSS LIMIT SWITCH...................................................................................8.20

8.4. ADJUSTING THE WEIGHT STACK CABLE TENSION ............................................................................................. 8.21

8.5. ADJUSTING THE PRESTART CABLE TENSION.....................................................................................................8.22

8.5.1. Adjusting the primary prestart cable tension......................................................................................8.22

8.5.2. Adjusting the secondary prestart cable tension..................................................................................8.23

8.6. ADJUSTING THE LEVER CABLE ........................................................................................................................ 8.24

8.7. ADJUSTING THE DOUBLING CABLE ..................................................................................................................8.25

8.8. ADJUSTING THE ZERO SENSOR POSITION..........................................................................................................8.26

8.9. ADJUSTING THE POSITION OF THE WEIGHT STACK SELECTION SYSTEM ............................................................8.27

8.10. ADJUSTING THE TENSION OF THE WEIGHT STACK SELECTION CHAIN................................................................8.28

8.11. ADJUSTING THE PRIMARY SHAFT - SECONDARY SHAFT CHAIN ALIGNMENT .....................................................8.29

8.12. ADJUSTING THE PRIMARY SHAFT - SECONDARY SHAFT CHAIN TENSION...........................................................8.30

8.13. ADJUSTING THE RELEASE CABLE TENSION.......................................................................................................8.31

8.14. ADJUSTING THE CURRENT LIMIT ON THE WSMI AND SAMI BOARD...............................................................8.32

8.15. LCD CONTRAST ..............................................................................................................................................8.33

8.16. BUZZER TONE .................................................................................................................................................8.34

9. CONFIGURING THE MACHINE.......................................................................................................................9.1

9.1. CONFIGURING PARAMETER DEFAULTS...............................................................................................................9.1

9.2. CONFIGURING THE TECHNICAL PARAMETERS ....................................................................................................9.1

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9.2.1. Machine code........................................................................................................................................9.2

9.2.2. Offset zero sensor .................................................................................................................................9.2

9.2.3. Number of pulses for weight stack selection.........................................................................................9.3

9.2.4. Weight stack motor inertia.................................................................................................................... 9.3

9.2.5. Weight stack motor selection window...................................................................................................9.4

9.2.6. Distance between plates .......................................................................................................................9.4

9.2.7. Number of pulses for seat selection ......................................................................................................9.5

9.2.8. Seat offset position 0.............................................................................................................................9.6

9.2.9. Seat offset position 9.............................................................................................................................9.6

9.2.10. Seat motor inertia .................................................................................................................................9.7

9.2.11. Minimum ROM length ..........................................................................................................................9.7

9.2.12. Default ROM start ................................................................................................................................9.8

9.2.13. Default ROM length..............................................................................................................................9.8

9.2.14. %ROM first rep.....................................................................................................................................9.9

9.3. CONFIGURING THE USER PARAMETERS............................................................................................................ 9.11

9.3.1. Language............................................................................................................................................9.11

9.3.2. Unit of measure ..................................................................................................................................9.11

9.3.3. Using the additional weight................................................................................................................9.12

9.3.4. Using the function keys.......................................................................................................................9.12

9.3.5. Number of which repetition to use for ROM acquisition....................................................................9.12

9.3.6. “Time-out” setting..............................................................................................................................9.12

9.3.7. Setting the default seat position..........................................................................................................9.13

9.3.8. Enable pacer.......................................................................................................................................9.13

9.3.9. Pacer speed.........................................................................................................................................9.14

9.3.10. Time before load.................................................................................................................................9.14

9.3.11. Perform auto-configuration procedure ..............................................................................................9.14

9.4. TABLE OF FACTORY SETTINGS.........................................................................................................................9.16

9.4.1. User parameters ................................................................................................................................. 9.16

9.4.2. ROM Parameters................................................................................................................................9.16

9.4.3. BOSCH weight stack motor parameters .............................................................................................9.16

9.4.4. Plate distance .....................................................................................................................................9.17

9.4.5. Seat motor parameters........................................................................................................................9.17

9.5. DISPLAYING WORKING PARAMETERS ..............................................................................................................9.18

9.5.1. Weight stack motor running time........................................................................................................9.18

9.5.2. Weight stack motor test cycles ............................................................................................................9.18

9.5.3. Number of relay switching cycles to move the weight stack motor upward........................................9.18

9.5.4. Number of relay switching cycles to move the weight stack motor downward...................................9.18

9.5.5. Number of fail signals produced by the weight stack motor interface board.....................................9.19

9.5.6. Seat motor running time .....................................................................................................................9.19

9.5.7. Seat motor test cycles..........................................................................................................................9.19

9.5.8. Number of relay switching cycles to move the seat motor upward.....................................................9.19

9.5.9. Number of relay switching cycles to move the seat motor downward ................................................9.20

9.5.10. Number of fail signals produced by the seat motor interface board...................................................9.20

9.5.11. Number of solenoid relay switching cycles.........................................................................................9.20

9.5.12. Machine running time.........................................................................................................................9.20

9.5.13. Number of repetitions carried out on the machine .............................................................................9.21

9.5.14. Total weight lifted using the machine.................................................................................................9.21

9.6. EDITING THE WORKING PARAMETERS.............................................................................................................. 9.22

9.6.1. Weight stack motor running time........................................................................................................9.22

9.6.2. Weight stack motor test cycles ............................................................................................................9.22

9.6.3. Number of relay switching cycles to move the weight stack motor upward........................................9.22

9.6.4. Number of relay switching cycles to move the weight stack motor downward...................................9.23

9.6.5. Number of fail signals produced by the weight stack motor interface board.....................................9.23

9.6.6. Seat motor running time .....................................................................................................................9.23

9.6.7. Seat motor test cycles..........................................................................................................................9.23

9.6.8. Number of relay switching cycles to move the seat motor upward.....................................................9.23

9.6.9. Number of relay switching cycles to move the seat motor downward ................................................9.24

9.6.10. Number of fail signals produced by the seat motor interface board...................................................9.24

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9.6.11. Number of solenoid relay switching cycles.........................................................................................9.24

9.6.12. Machine running time.........................................................................................................................9.24

9.6.13. Number of repetitions carried out on the machine .............................................................................9.25

9.6.14. Total weight lifted using the machine.................................................................................................9.25

10. SCHEDULED MAINTENANCE........................................................................................................................ 10.1

10.1. EXTERNAL CLEANING .....................................................................................................................................10.1

10.1.1. Preparing working conditions ............................................................................................................10.1

10.1.2. Cleaning operations ...........................................................................................................................10.1

10.2. INTERNAL CLEANING.......................................................................................................................................10.2

10.2.1. Preparing working conditions ............................................................................................................10.2

10.2.2. Cleaning operations ...........................................................................................................................10.2

10.3. MECHANICAL OPERATIONS .............................................................................................................................10.3

10.3.1. Preparing working conditions ............................................................................................................10.3

10.3.2. Check the weight stack selection system.............................................................................................10.3

10.3.3. Check the weight stack plate springs.................................................................................................. 10.3

10.3.4. Check the cross, bars and weight stack plates....................................................................................10.3

10.3.5. Check the additional weight ...............................................................................................................10.4

10.3.6. Check the cables .................................................................................................................................10.4

10.3.7. Check the mechanisms........................................................................................................................10.4

10.3.8. Check the gas springs.........................................................................................................................10.4

10.3.9. Check the pulleys ................................................................................................................................10.4

10.3.10. Check the cam group .......................................................................................................................10.4

10.3.11. Check the primary and secondary shaft connection chain ..............................................................10.4

10.3.12. Check the lever limit switch buffers .................................................................................................10.5

10.3.13. Check the cross limit switch.............................................................................................................10.5

10.3.14. Check the Leg Press seat mechanism...............................................................................................10.5

10.3.15. Check the seat mechanism for other machines................................................................................10.5

10.3.16. Check the Leg Press back and shoulder rest ...................................................................................10.5

10.3.17. Check the wire encoder....................................................................................................................10.5

10.4. ELECTRICAL/ELECTRONIC OPERATIONS...........................................................................................................10.6

10.4.1. Preparing working conditions ............................................................................................................10.6

10.4.2. Check the wiring and connections......................................................................................................10.6

10.4.3. Check the display................................................................................................................................10.6

10.4.4. Check wear on components ................................................................................................................10.6

10.4.5. Check the component functions ..........................................................................................................10.7

10.5. SOFTWARE CONFIGURATION ...........................................................................................................................10.8

10.5.1. Preparing working conditions ............................................................................................................10.8

10.5.2. Configuration check ...........................................................................................................................10.8

11. APPENDIX ...........................................................................................................................................................11.1

11.1. CONFIGURATION PARAMETERS FOR EXERCISE ROM ACQUISITION..................................................................11.1

11.2. CALCULATING REPETITIONS ............................................................................................................................11.1

11.3. LOCATING THE SERIAL NUMBER ......................................................................................................................11.2

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1. GENERAL NOTICES

1.1. INTRODUCTION

This document is reserved for Technogym Service technicians, and is intended to provide
authorized personnel with the necessary information to correctly carry out repairs and maintenance.
A thorough knowledge of the technical information contained in this manual is essential for
completing the professional training of the operator.

In order to facilitate consultation, the paragraphs are accompanied by schematic illustrations
highlighting the topic covered.

This manual contains notices and symbols, which have a specific meaning:

WARNING: non observance may result in accident or injury.

ATTENTION: non observance may cause damage to the machine.

Information about the operation in progress.

OBSERVE: observation about the operation in progress.

1.2. RECOMMENDATIONS

Technogym recommends the following steps for planning repair procedures:

• Carefully evaluate the customer’s description of the machine malfunction and ask all the

necessary questions to clarify the symptoms of the problem.

• Clearly diagnose the causes of the problem. This manual provides the fundamental theoretical

basis, which must then be integrated by personal experience and attendance at the training
courses periodically offered by Technogym.

• Rationally plan the repair procedure so as to minimize the downtime necessary for procuring

spare parts, preparing tools, etc.

• Access the component to be repaired, avoiding any unnecessary operations. In this regard it will

be useful to refer to the disassembly sequence described in this manual.

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BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

1.3. GENERAL RULES FOR REPAIR PROCEDURES

1. Always mark any parts or positions which may be confused with each other at the time of

reassembly.

2. Use original Technogym spare parts and lubricants of the recommended brands.

3. Use special tools where specified.

4. Consult the technical circulars, which may contain more up-to-date information on adjustments

and maintenance than those contained in this manual.

5. Before starting the repair procedure, make sure that the recommended tools are available and in

good condition.

6. For the procedures described in this manual, use only the specified tools.

OBSERVE: The tool sizes quoted in this manual are expressed in mm.

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BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

2. TECHNICAL SPECIFICATIONS

2.1. MECHANICAL CHARACTERISTICS

The sizes quoted in the following figures must be considered as minimum dimensions

easily reachable disassembling some parts of the machines such as seat, footboard, and
casing or display holder.

OBSERVE: The sizes quoted in the following figures are expressed in mm.

2.1.1. ABDOMINAL CRUNCH

2.1.2. LOWER BACK

Page 2.1

2.1.3. LEG EXTENSION

2.1.4. LEG CURL

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

2.1.5. VERTICAL TRACTION

Page 2.2

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

2.1.6. SHOULDER PRESS

2.1.7. CHEST PRESS

2.1.8. ROWING TORSO

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BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

2.1.9. LEG PRESS

In the following table, the dimensions are calculated including the space occupied when levers are
moving:

MACHINE Length

mm

Abdominal Crunch 1400 1000 1450
Lower Back 1400 1000 1450
Leg Extension 1550 1000 1450
Leg Curl 1550 1000 1450
Vertical Traction 2000 1200 1960
Shoulder Press 2000 1200 1960
Chest Press 1950 1200 1450
Rowing Torso 1650 1050 1550
Leg Press 2670 1020 1600

Width

mm

2.2. ELECTRICAL CHARACTERISTICS

MACHINE Mains

voltage

Abdominal Crunch
Lower Back
Leg Extension
Leg Curl
Vertical Traction
Shoulder Press
Chest Press
Rowing Torso
Leg Press

115 – 230 Vac
115 – 230 Vac
115 – 230 Vac
115 – 230 Vac
115 – 230 Vac
115 – 230 Vac
115 – 230 Vac
115 – 230 Vac
115 – 230 Vac

Frequency Consumption Fuses

50 - 60 Hz 100 VA 5x20 1.6 A slow blow
50 - 60 Hz 100 VA 5x20 1.6 A slow blow
50 - 60 Hz 200 VA 5x20 2.0 A slow blow
50 - 60 Hz 200 VA 5x20 2.0 A slow blow
50 - 60 Hz 200 VA 5x20 2.0 A slow blow
50 - 60 Hz 200 VA 5x20 2.0 A slow blow
50 - 60 Hz 200 VA 5x20 2.0 A slow blow
50 - 60 Hz 200 VA 5x20 2.0 A slow blow
50 - 60 Hz 400 VA 5x20 5.0 A slow blow

Height

mm

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BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

2.3. AMBIENT SPECIFICATIONS

Temperature

Humidity

Operating 5° to 35° C
Storage -20 to 55° C
Operating 30% to 80% non-condensing
Storage 5% to 85% non-condensing

2.4. CONFORMITY TO REGULATIONS

The machine conforms to the following directives:

EMI

Safety

Directive

Moreover:

• Machines do not produce electromagnetic disturbances.

• Class 1 machines.

• Machines with Type B applied parts.

• Ordinary machines not protected against water penetration.

• Machine not suitable for use in presence of an inflammable anesthetic mixture of air, oxygen or

protoxide nitrogen.

• Machines for continual use.

Europe USA

EN 60601-1-2

EN 60601-1

EN 957-1
73/23/CEE
93/68/CEE

89/336/CEE

UL 2601-1

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2.5. UNIFIED BOARD VERSION

2.5.1. TYPE A WIRING DIAGRAM

This diagram is for Abdominal Crunch and Lower Back.

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BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

2.5.1.1. Connectors

• Power socket

Name Type of connector Connection

CN11 3 male Faston 6.3x0.8 110/220 Vac line: phase, neutral, earth

• Power switch

Name Type of connector Connection

CN13 2 male Faston 6.3x0.8 110/220 Vac line: phase, neutral
CN14 2 male Faston 6.3x0.8 110/220 Vac line: phase, neutral

• Fuse

Name Type of connector Connection

CN15 2 male Faston 4.8x0.5 110/220 Vac line: phase, neutral
CN16 2 male Faston 4.8x0.5 110/220 Vac line: phase, neutral

• Filter

Name Type of connector Connection

CN17 3 male Faston 6.3x0.8 110/220 Vac line: phase, neutral, earth
CN18 2 male Faston M5 screw slot 110/220 Vac line: phase, neutral, earth

• Voltage selector board (labeled GF990505 - order code 0WQ123)

Name Type of connector Connection

CN1 3-pin female AMP MNL 110/220 Vac line: phase, neutral
CN2 3-pin terminal board transformer input line: phase, neutral

• Power supply (order code 0WA040)

Name Type of connector Connection

CN1 6-pin male PANDUIT 110/220 Vac line: phase, neutral, earth
CN2 6-pin male PANDUIT Low voltage: +12 Vdc, +5 Vdc, ground
CN7 Male Faston for printed circuit 6.3x0.8 Earth contact

• CPU Board (labeled GF961223 - order code 0WQ067)

Name Type of connector Connection

K1 4-pin male AMP MODU I Low voltage: +12 Vdc, +5 Vdc, ground
K3 6-pin male AMP MODU II Serial: RS-232 to FPGA
K4 9x2-pin male AMP MODU II Signals: I/O connection
K5 4x2-pin male AMP MODU II Signals: I/O connection
K6 4-pin male AMP MODU II TLCBR
K15 6-pin male AMP MODU II External serial port

Page 2.7

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

• Bio Servo board (labeled GF981005 - order code 0WQ121)

Name Type of connector Connection

CN1 6-pin male AMP MINIFIT 24 Vdc weight stack motor with reed
CN3 6-pin male AMP MODU II Encoder and Solenoid
CN4 2-pin male AMP MINIFIT Zero sensor signal
CN7 18-pin male AMP MODU II Signals: CPU connection
CN8 4-pin male AMP MODU I Low voltage: +12 Vdc, +5 Vdc, ground
CN9 4-pin male AMP MODU I Low voltage: +12 Vdc, +5 Vdc, ground
CN10 2-pin terminal board 18 Vac 10A power supply
CE1 2-pin male AMP MODU II Signals: safety device input

• Patch cords

Name Type of connector Connection

CN21 6-pin open male AMP MINIFIT 24 Vdc weight stack motor with reed
CN23 6-pin open male AMP MODU II Encoder signals
CN24 4-pin open male AMP MODU II Solenoid power supply
CN25 4-pin open female AMP MODU II Solenoid power supply
CN26 4-pin open male AMP MODU II Solenoid power supply
CN27 2-pin open male AMP MODU II Zero sensor signal

2.5.1.2. Cables

Power socket

CN11

Faston Earth Yellow–green - Slot
Faston Neutral Black Faston ­Faston Phase Black Faston -

Power switch

CN14

Faston Neutral Black Faston
Faston Phase Black Faston

BS-11: High-voltage power cable

Power socket – Power switch – Earth node

Signal Color Power switch

CN13

BS-12: High-voltage power cable

Power switch – Fuses

Signal Color Fuses

CN15

PE

Page 2.8

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

BS-13: High-voltage power cable

Fuses – Filter – Earth node

Fuses
CN16

Faston Neutral Black Faston ­Faston Phase Black Faston -

- Earth Yellow–

Signal Color Filter

CN17

Faston Slot

green

PE

BS-14/S: High-voltage power cable

Filter – Power supply – 110/230 Selector switch

Filter
CN18

Slot Ground Yellow 1 -

Faston Neutral Blue

Faston Phase Black

Signal Color Power supply

CN1

4 -

- 2

6 -

- 1

Selector switch

CN1

BS-7/L: Low-voltage power cable
Power supply – Bio Driver Board

Power supply

CN2 CN7

1 - + 12 Vdc Red 1
3 - + 5 Vdc Orange 4
4 - Ground Gray 3
5 Faston Earth Black 2

The connection between connector CN7 and pin 5 on connector CN2, both on the power supply,
serves to ground the low voltage grounding socket (0 V).

Signal Color Bio driver

board

CN9

BS-4: Low voltage cable

Bio Driver Board – CPU Board

Bio driver

board

CN8

1 + 12 Vdc Black 1
2 Ground Red 2
3 Ground White 3
4 + 5 Vdc Green 4

Signal Color CPU Board

K1

Page 2.9

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

BS-6/2: Signal cable

CPU Board – Bio Driver Board

CPU Board

K4 K3 K5

1 Ground Black 1
2 Ground Purple 2
3 Weight stack motor up Blue 3
5 Weight stack motor down Black 5
7 Weight stack motor alarm White–red 7

9 Weight stack motor pulses White–green 9
15 Solenoid status Green 15
17 Solenoid enable White 13

3 Tx from FPGA to CPU White–yellow 12
6 Reset to FPGA Yellow-red 18
3 + zero sensor White–black 17

Signal Color Bio Driver

Board

CN7

BS-00: Zero sensor extension cable

Bio Driver Board – Patch

Bio Driver

Board

CN4

1 Signal White 1
2 Ground Black 2

Signal Color Open

CN27

BS-0: Zero sensor cable

Zero sensor – Patch

Zero sensor Signal Color Open

CN27

Output

Signal White 1
Ground Black 2

BS-2/2R: Weight stack motor cable

Bio Driver Board – Patch cord

Bio Driver

Board

CN1

1 + motor Black 1
2 - motor Red 2
4 + 12 Vdc White 4
5 Pulses Green 5
6 Ground Orange 6

Signal Color Open

CN21

Page 2.10

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

CAUTION: On some equipment this cable could be divided into two parts.

BS-9/2: Weight stack cable

Bio Driver Board – Patch cord

Signal Color

CN3

1 Channel A Black 1 ­2 Channel B Red 2 ­3 +12 Vdc White 3 ­4 Ground Green 4 ­5 + solenoid Orange - 4
6 Solenoid ground Blue - 3

BS-10: Solenoid extension cord

Patch – Patch

Patch
CN25

3 + solenoid Blue 3
4 Solenoid ground Red 4

Signal Color Open

BS-232: Serial output cable

CPU Board – Serial connector

CPU Board

K15

2 ground Black 5
3 Tx to PC Yellow 2
4 Rx from PC Green 3

Signal Color Serial connector

BS-TLCBR: TGS connector cable

CPU Board – TLCBR

CPU Board

K6

1 + 12 Vdc Red 8
2 ground Black 6
3 Tx to TGS Yellow 2
4 Rx from TGS Green 1

Signal Color TLCBR

Open Bio Driver Board

CN23 CN24

CN26

Page 2.11

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

2.5.2. TYPE B WIRING DIAGRAM

This diagram is for Leg Curl, Vertical Traction, Shoulder Press, Chest Press and Rowing Torso.

Page 2.12

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

2.5.2.1. Connectors

• Power socket

Name Type of connector Connection

CN11 3 male Faston 6.3x0.8 110/220 Vac line: phase, neutral, earth

• Power switch

Name Type of connector Connection

CN13 2 male Faston 6.3x0.8 110/220 Vac line: phase, neutral
CN14 2 male Faston 6.3x0.8 110/220 Vac line: phase, neutral

• Fuse

Name Type of connector Connection

CN15 2 male Faston 4.8x0.5 110/220 Vac line: phase, neutral
CN16 2 male Faston 4.8x0.5 110/220 Vac line: phase, neutral

• Filter

Name Type of connector Connection

CN17 3 male Faston 6.3x0.8 110/220 Vac line: phase, neutral, earth
CN18 2 male Faston M5 screw slot 110/220 Vac line: phase, neutral, earth

• Voltage selector board (labeled GF990505 - order code 0WQ123)

Name Type of connector Connection

CN1 3-pin female AMP MNL 110/220 Vac line: phase, neutral
CN2 3-pin terminal board transformer input line: phase, neutral

• Power supply (order code 0WA040)

Name Type of connector Connection

CN1 6-pin male PANDUIT 110/220 Vac line: phase, neutral, earth
CN2 6-pin male PANDUIT Low voltage: +12 Vdc, +5 Vdc, ground
CN7 Male Faston for printed circuit 6.3x0.8 Earth contact

• CPU Board (labeled GF961223 - order code 0WQ067)

Name Type of connector Connection

K1 4-pin male AMP MODU I Low voltage: +12 Vdc, +5 Vdc, ground
K3 6-pin male AMP MODU II Serial: RS-232 to FPGA
K4 9x2-pin male AMP MODU II Signals: I/O connection
K5 4x2-pin male AMP MODU II Signals: I/O connection
K6 4-pin male AMP MODU II TLCBR
K15 6-pin male AMP MODU II External serial port

Page 2.13

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

• Bio Servo board (labeled GF981005 - order code 0WQ121)

Name Type of connector Connection

CN1 6-pin male AMP MINIFIT 24 Vdc weight stack motor with reed
CN2 6-pin male AMP MINIFIT 24 Vdc seat adjustment motor with reed
CN3 6-pin male AMP MODU II Encoder and Solenoid
CN4 2-pin male AMP MINIFIT Zero sensor signal
CN7 18-pin male AMP MODU II Signals: CPU connection
CN8 4-pin male AMP MODU I Low voltage: +12 Vdc, +5 Vdc, ground
CN9 4-pin male AMP MODU I Low voltage: +12 Vdc, +5 Vdc, ground
CN10 2-pin terminal board 18 Vac 10A power supply
CE1 2-pin male AMP MODU II Signals: safety device input

• Patch cords

Name Type of connector Connection

CN21 6-pin open male AMP MINIFIT 24 Vdc weight stack motor with reed
CN22 6-pin open male AMP MINIFIT 24 Vdc seat adjustment motor with reed
CN23 6-pin open male AMP MODU II Encoder signals
CN24 4-pin open male AMP MODU II Solenoid power supply
CN25 4-pin open female AMP MODU II Solenoid power supply
CN26 4-pin open male AMP MODU II Solenoid power supply
CN27 2-pin open male AMP MODU II Zero sensor signal

2.5.2.2. Cables

Power socket

CN11

Faston Earth Yellow–green - Slot
Faston Neutral Black Faston ­Faston Phase Black Faston -

Power switch

CN14

Faston Neutral Black Faston
Faston Phase Black Faston

BS-11: High-voltage power cable

Power socket – Power switch – Earth node

Signal Color Power switch

CN13

BS-12: High-voltage power cable

Power switch – Fuses

Signal Color Fuses

CN15

PE

Page 2.14

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

BS-13: High-voltage power cable

Fuses – Filter – Earth node

Fuses
CN16

Faston Neutral Black Faston ­Faston Phase Black Faston -

- Earth Yellow–

Signal Color CN17

Filter

Faston Slot

green

PE

BS-14/S: High-voltage power cable

Filter – Power supply – 110/230 Selector switch

Filter
CN18

Slot Ground Yellow 1 -

Faston Neutral Blue

Faston Phase Black

Signal Color Power supply

CN1

4 -

- 2

6 -

- 1

Selector switch

CN1

BS-7/L: Low-voltage power cable
Power supply – Bio Driver Board

Power supply

CN2 CN7

1 - + 12 V Red 1
3 - + 5 V Orange 4
4 - Ground Gray 3
5 Faston Earth Black 2

The connection between connector CN7 and pin 5 on connector CN2, both on the power supply,
serves to ground the low voltage grounding socket (0 V).

Signal Color Bio driver

board

CN9

BS-4: Low voltage cable

Bio Driver Board – CPU Board

Bio driver

board

CN8

1 + 12 Vdc Black 1
2 Ground Red 2
3 Ground White 3
4 + 5 Vdc Green 4

Signal Color CPU Board

K1

Page 2.15

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

BS-6/2: Signal cable

CPU Board – Bio Driver Board

CPU Board

K4 K3 K5

1 Ground Black 1

2 Ground Purple 2

3 Weight stack motor up Blue 3

4 Seat motor up Brown 4

5 Weight stack motor down Black 5

6 Seat motor down Yellow 6

7 Weight stack motor alarm White–red 7

8 Seat motor Alarm Pink 8

9 Weight stack motor pulses White–green 9
10 Seat motor Pulses Red 10
15 Solenoid status Green 15
17 Solenoid enable White 13

3 Tx from FPGA to CPU White–yellow 12
6 Reset to FPGA Yellow-red 18
3 + zero sensor White–black 17

CAUTION: On the Chest Press, the Vertical Traction and the Shoulder Press, the BS-4

and BS-6 cables are divided into two parts.

Signal Color Bio Driver

Board

CN7

BS-00: Zero sensor extension cable

Bio Driver Board – Patch

Bio Driver

Board

CN4

1 Signal White 1
2 Ground Black 2

Signal Color Open

CN27

BS-0: Zero sensor cable

Zero sensor – Patch

Zero sensor Signal Color Open

CN27

Output

Signal White 1
Ground Black 2

Page 2.16

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

BS-2/2R: Weight stack motor cable

Bio Driver Board – Patch cord

Bio Driver

Board

CN1

1 + motor Black 1
2 - motor Red 2
4 + 12 Vdc White 4
5 Pulses Green 5
6 Ground Orange 6

CAUTION: On some equipment this cable could be divided into two parts.

Signal Color Open

BS-2/2S: Seat motor cable

Bio Driver Board – Patch cord

Bio Driver

Board

CN2

1 + motor White 1
2 - motor Blue 2
5 Pulses Red 5
6 Ground Black 6

CAUTION: On some equipment this cable could be divided into two parts.

Signal Color Open

BS-9/2: Weight stack cable

Bio Driver Board – Patch cord

Signal Color

CN3

1 Channel A Black 1 ­2 Channel B Red 2 ­3 +12 Vdc White 3 ­4 Ground Green 4 ­5 + solenoid Orange - 4
6 Solenoid ground Blue - 3

CN21

CN22

Open Bio Driver Board

CN23 CN24

Page 2.17

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

BS-10: Solenoid extension cord

Patch – Patch

Patch
CN25

3 + solenoid Blue 3
4 Solenoid ground Red 4

Signal Color Open

CN26

BS-232: Serial output cable

CPU Board – Serial connector

CPU Board

K15

2 ground Black 5
3 Tx to PC Yellow 2
4 Rx from PC Green 3

Signal Color Serial connector

BS-TLCBR: TGS connector cable

CPU Board – TLCBR

CPU Board

K6

1 + 12 V Red 8
2 ground Black 6
3 Tx to TGS Yellow 2
4 Rx from TGS Green 1

Signal Color TLCBR

Page 2.18

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

2.5.3. TYPE C WIRING DIAGRAM

This diagram is for Leg Extension.

Page 2.19

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

2.5.3.1. Connectors

• Power socket

Name Type of connector Connection

CN11 3 male Faston 6.3x0.8 110/220 Vac line: phase, neutral, earth

• Power switch

Name Type of connector Connection

CN13 2 male Faston 6.3x0.8 110/220 Vac line: phase, neutral
CN14 2 male Faston 6.3x0.8 110/220 Vac line: phase, neutral

• Fuse

Name Type of connector Connection

CN15 2 male Faston 4.8x0.5 110/220 Vac line: phase, neutral
CN16 2 male Faston 4.8x0.5 110/220 Vac line: phase, neutral

• Filter

Name Type of connector Connection

CN17 3 male Faston 6.3x0.8 110/220 Vac line: phase, neutral, earth
CN18 2 male Faston M5 screw slot 110/220 Vac line: phase, neutral, earth

• Voltage selector board (labeled GF990505 - order code 0WQ123)

Name Type of connector Connection

CN1 3-pin female AMP MNL 110/220 Vac line: phase, neutral
CN2 3-pin terminal board transformer input line: phase, neutral

• Power supply (order code 0WA040)

Name Type of connector Connection

CN1 6-pin male PANDUIT 110/220 Vac line: phase, neutral, earth
CN2 6-pin male PANDUIT Low voltage: +12 Vdc, +5 Vdc, ground
CN7 Male Faston for printed circuit 6.3x0.8 Earth contact

• CPU Board (labeled GF961223 - order code 0WQ067)

Name Type of connector Connection

K1 4-pin male AMP MODU I Low voltage: +12 Vdc, +5 Vdc, ground
K3 6-pin male AMP MODU II Serial: RS-232 to FPGA
K4 9x2-pin male AMP MODU II Signals: I/O connection
K5 4x2-pin male AMP MODU II Signals: I/O connection
K6 4-pin male AMP MODU II TLCBR
K15 6-pin male AMP MODU II External serial port

Page 2.20

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

• Bio Servo board (labeled GF981005 - order code 0WQ121)

Name Type of connector Connection

CN1 6-pin male AMP MINIFIT 24 Vdc weight stack motor with reed
CN2 6-pin male AMP MINIFIT 24 Vdc seat adjustment motor with reed
CN3 6-pin male AMP MODU II Encoder and Solenoid
CN4 2-pin male AMP MINIFIT Zero sensor signal
CN7 18-pin male AMP MODU II Signals: CPU connection
CN8 4-pin male AMP MODU I Low voltage: +12 Vdc, +5 Vdc, ground
CN9 4-pin male AMP MODU I Low voltage: +12 Vdc, +5 Vdc, ground
CN10 2-pin terminal board 18 Vac 10A power supply
CE1 2-pin male AMP MODU II Signals: safety device input

• Sensor interface board (labeled GF991031 - order code 0WQ00007)

Name Type of connector Connection

CN1 2-pin open male AMP MINIFIT Safety sensor input signal
CN2 4-pin male AMP MODU II Safety sensor input signal to driver board
CN3 2-pin male AMP MODU II Reset

• Patch cords

Name Type of connector Connection

CN21 6-pin open male AMP MINIFIT Weight stack motor and reed power

supply
CN23 6-pin open male AMP MODU II Encoder signals
CN24 4-pin open male AMP MODU II Solenoid power supply
CN25 4-pin open female AMP MODU II Solenoid power supply
CN26 4-pin open male AMP MODU II Solenoid power supply
CN27 2-pin open male AMP MODU II Zero sensor signal
CN28 2-pin open female AMP MINIFIT Safety sensor signal
CN29 2-pin open male AMP MINIFIT Safety sensor signal

2.5.3.2. Cables

Power socket

CN11

Faston Earth Yellow–green - Slot
Faston Neutral Black Faston ­Faston Phase Black Faston -

BS-11: High-voltage power cable

Power socket – Power switch – Earth node

Signal Color Power switch

CN13

PE

Page 2.21

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

BS-12: High-voltage power cable

Power switch – Fuses

Power switch

CN14

Faston Neutral Black Faston
Faston Phase Black Faston

Signal Color Fuses

CN15

BS-13: High-voltage power cable

Fuses – Filter – Earth node

Fuses
CN16

Faston Neutral Black Faston ­Faston Phase Black Faston -

- Earth Yellow–

Signal Color CN17

Filter

Faston Slot

green

PE

BS-14/S: High-voltage power cable

Filter – Power supply – 110/230 Selector switch

Filter
CN18

Slot Ground Yellow 1 -

Faston Neutral Blue

Faston Phase Black

Signal Color Power supply

CN1

4 -

- 2

6 -

- 1

Selector switch

CN1

BS-7/L: Low-voltage power cable
Power supply – Bio Driver Board

Power supply

CN2 CN7

1 - + 12 V Red 1
3 - + 5 V Orange 4
4 - Ground Gray 3
5 Faston Earth Black 2

The connection between connector CN7 and pin 5 on connector CN2, both on the power supply,
serves to ground the low voltage grounding socket (0 V).

Signal Color Bio driver

board

CN9

Page 2.22

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

BS-4: Low voltage cable

Bio Driver Board – CPU Board

Bio driver

board

CN8

1 + 12 Vdc Black 1
2 Ground Red 2
3 Ground White 3
4 + 5 Vdc Green 4

Signal Color CPU Board

BS-6/2: Signal cable

CPU Board – Bio Driver Board

CPU Board

K4 K3 K5

1 Ground Black 1
2 Ground Purple 2
3 Weight stack motor up Blue 3
4 Seat motor up Brown 4
5 Weight stack motor down Black 5
6 Seat motor down Yellow 6
7 Weight stack motor alarm White–red 7
8 Seat motor Alarm Pink 8

9 Weight stack motor pulses White–green 9
10 Seat motor Pulses Red 10
15 Solenoid status Green 15
17 Solenoid enable White 13

3 Tx from FPGA to CPU White–yellow 12
6 Reset to FPGA Yellow-red 18
3 + zero sensor White–black 17

Signal Color Bio Driver

BS-00: Zero sensor extension cable

Bio Driver Board – Patch

Bio Driver

Board

CN4

1 Signal White 1
2 Ground Black 2

Signal Color Open

K1

Board

CN7

CN27

Page 2.23

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

BS-0: Zero sensor cable

Zero sensor – Patch

Zero sensor Signal Color Open

CN27

Output

Signal White 1
Ground Black 2

BS-2/2R: Weight stack motor cable

Bio Driver Board – Patch cord

Bio Driver

Board

CN1

1 + motor Black 1
2 - motor Red 2
4 + 12 Vdc White 4
5 Pulses Green 5
6 Ground Orange 6

Signal Color Open

CN21

BS-2S: Seat motor cable

Bio Driver Board – Motor

Bio Driver

Board

CN2

1 + motor White 1
2 - motor Blue 2
5 Pulses Red 5
6 Ground Black 6

Signal Color Motor

BS-9/2: Weight stack cable

Bio Driver Board – Patch cord

Signal Color

CN3

1 Channel A Black 1 ­2 Channel B Red 2 ­3 +12 Vdc White 3 ­4 Ground Green 4 ­5 + solenoid Orange - 4
6 Solenoid ground Blue - 3

Open Bio Driver Board

CN23 CN24

Page 2.24

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

BS-10: Solenoid extension cord

Patch – Patch

Patch
CN25

3 + solenoid Blue 3
4 Solenoid ground Red 4

Signal Color Open

BS-232: Serial output cable

CPU Board – Serial connector

CPU Board

K15

2 ground Black 5
3 Tx to PC Yellow 2
4 Rx from PC Green 3

Signal Color Serial connector

BS-TLCBR: TGS connector cable

CPU Board – TLCBR

CPU Board

K6

1 + 12 V Red 8
2 ground Black 6
3 Tx to TGS Yellow 2
4 Rx from TGS Green 1

Signal Color TLCBR

BS-30: Signal sensor cable

Bio Driver Board – Sensor interface Board

Bio Driver Board

CE1 CN10

1 - +12 Vdc Red 1
2 - Alarm White 2

- 2 Ground Black 3

Signal Color Sensor interface

BS-31: Sensor cable

Sensor Interface Board – Sensor

Sensor Interface

Board

CN1

1 + Signal White 1
2 - Signal Black 2

Signal Color Open

CN26

Board

CN2

CN29

Page 2.25

2.5.4. TYPE D WIRING DIAGRAM

This diagram is for Leg Press.

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

Page 2.26

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

2.5.4.1. Connectors

• Power socket

Name Type of connector Connection

CN11 3 male Faston 6.3x0.8 110/220 Vac line: phase, neutral, earth

• Power switch

Name Type of connector Connection

CN13 2 male Faston 6.3x0.8 110/220 Vac line: phase, neutral
CN14 2 male Faston 6.3x0.8 110/220 Vac line: phase, neutral

• Fuse

Name Type of connector Connection

CN15 2 male Faston 4.8x0.5 110/220 Vac line: phase, neutral
CN16 2 male Faston 4.8x0.5 110/220 Vac line: phase, neutral

• Filter

Name Type of connector Connection

CN17 3 male Faston 6.3x0.8 110/220 Vac line: phase, neutral, earth
CN18 2 male Faston M5 screw slot 110/220 Vac line: phase, neutral, earth

• Voltage selector board (labeled GF990505 - order code 0WQ123)

Name Type of connector Connection

CN1 3-pin female AMP MNL 110/220 Vac line: phase, neutral
CN2 3-pin terminal board transformer input line: phase, neutral

• Power supply (order code 0WA040)

Name Type of connector Connection

CN1 6-pin male PANDUIT 110/220 Vac line: phase, neutral, earth
CN2 6-pin male PANDUIT Low voltage: +12 Vdc, +5 Vdc, ground
CN7 Male Faston for printed circuit 6.3x0.8 Earth contact

• CPU Board (labeled GF961223 - order code 0WQ067)

Name Type of connector Connection

K1 4-pin male AMP MODU I Low voltage: +12 Vdc, +5 Vdc, ground
K3 6-pin male AMP MODU II Serial: RS-232 to FPGA
K4 9x2-pin male AMP MODU II Signals: I/O connection
K5 4x2-pin male AMP MODU II Signals: I/O connection
K6 4-pin male AMP MODU II TLCBR
K15 6-pin male AMP MODU II External serial port

Page 2.27

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

• Bio Servo board (labeled GF981005 - order code 0WQ00056)

Name Type of connector Connection

CN1 6-pin male AMP MINIFIT 24 Vdc weight stack motor with reed
CN3 6-pin male AMP MODU II Encoder and Solenoid
CN4 2-pin male AMP MINIFIT Zero sensor signal
CN6 6-pin male AMP MODU II Signals: LP driver board
CN7 18-pin male AMP MODU II Signals: CPU connection
CN8 4-pin male AMP MODU I Low voltage: +12 Vdc, +5 Vdc, ground
CN9 4-pin male AMP MODU I Low voltage: +12 Vdc, +5 Vdc, ground
CN10 2-pin terminal board 18 Vac 10A power supply
CE1 2-pin male AMP MODU II Signals: safety device input

• LP driver board (labeled GF981027 - order code 0WQ00233AA)

Name Type of connector Connection

CN1 2-pin male AMP MATE’N’LOCK 48Vdc LP seat motor
CN2 2-pin terminal board 38 Vac 6A power supply
CN3 6-pin male AMP MODU II Signals: servo board
CN4 4x2-pin male AMP MODU II Encoder and microswitches
CE1 2-pin male AMP MODU II Signals: safety device input

• Sensor interface board (labeled GF991031 - order code 0WQ00007)

Name Type of connector Connection

CN1 2-pin open male AMP MINIFIT Safety sensor input signal
CN2 4-pin male AMP MODU II Safety sensor input signal to driver board
CN3 2-pin male AMP MODU II Reset

• Patch cords

Name Type of connector Connection

CN21 6-pin open male AMP MINIFIT 24 Vdc weight stack motor with reed
CN23 6-pin open male AMP MODU II Encoder signals
CN24 4-pin open male AMP MODU II Solenoid power supply
CN25 4-pin open female AMP MODU II Solenoid power supply
CN26 4-pin open male AMP MODU II Solenoid power supply
CN27 2-pin open male AMP MODU II Zero sensor signal
CN28 2-pin open female AMP MINIFIT Safety sensor signal
CN30 2-pin open female AMP MINIFIT Emergency button

Page 2.28

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

2.5.4.2. Cables

BS-11: High-voltage power cable

Power socket – Power switch – Earth node

Power socket

CN11

Faston Earth Yellow–green - Slot
Faston Neutral Black Faston ­Faston Phase Black Faston -

Signal Color Power switch

BS-12: High-voltage power cable

Power switch – Fuses

Power switch

CN14

Faston Neutral Black Faston
Faston Phase Black Faston

Signal Color Fuses

BS-13: High-voltage power cable

Fuses – Filter – Earth node

Fuses
CN16

Faston Neutral Black Faston ­Faston Phase Black Faston -

- Earth Yellow–

Signal Color Filter

BS-14/S: High-voltage power cable

Filter – Power supply – 110/230 Selector switch

Filter
CN18

Slot Ground Yellow 1 -

Faston Neutral Blue

Faston Phase Black

Signal Color Power supply

PE

CN13

CN15

PE

CN17

Faston Slot

green

Selector switch

CN1

4 -

- 2

6 -

- 1

CN1

Page 2.29

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

BS-7/L: Low-voltage power cable
Power supply – Bio Driver Board

Power supply

CN2 CN7

1 - + 12 Vdc Red 1
3 - + 5 Vdc Orange 4
4 - Ground Gray 3
5 Faston Earth Black 2

The connection between connector CN7 and pin 5 on connector CN2, both on the power supply,
serves to ground the low voltage grounding socket (0 V).

Signal Color Bio driver

board

CN9

BS-4: Low voltage cable

Bio Driver Board – CPU Board

Bio driver

board

CN8

1 + 12 Vdc Black 1
2 Ground Red 2
3 Ground White 3
4 + 5 Vdc Green 4

Signal Color CPU Board

K1

BS-6/2: Signal cable

CPU Board – Bio Driver Board

CPU Board

K4 K3 K5

1 Ground Black 1

2 Ground Purple 2

3 Weight stack motor up Blue 3

4 Seat motor up Brown 4

5 Weight stack motor down Black 5

6 Seat motor down Yellow 6

7 Weight stack motor alarm White–red 7

8 Seat motor Alarm Pink 8

9 Weight stack motor pulses White–green 9
10 Seat motor Pulses Red 10
15 Solenoid status Green 15
17 Solenoid enable White 13

3 Tx from FPGA to CPU White–yellow 12
6 Reset to FPGA Yellow-red 18
3 + zero sensor White–black 17

Signal Color Bio Driver

Board

CN7

Page 2.30

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

BS-00: Zero sensor extension cable

Bio Driver Board – Patch

Bio Driver

Board

CN4

1 Signal White 1
2 Ground Black 2

Signal Color Open

BS-0: Zero sensor cable

Zero sensor – Patch

Zero sensor Signal Color Open

Output

Signal White 1
Ground Black 2

BS-2/2R: Weight stack motor cable

Bio Driver Board – Patch cord

Bio Driver

Board

CN1

1 + motor Black 1
2 - motor Red 2
4 + 12 Vdc White 4
5 Pulses Green 5
6 Ground Orange 6

Signal Color Open

BS-9/2: Weight stack cable

Bio Driver Board – Patch cord

Signal Color

CN3

1 Channel A Black 1 ­2 Channel B Red 2 ­3 +12 Vdc White 3 ­4 Ground Green 4 ­5 + solenoid Orange - 4
6 Solenoid ground Blue - 3

CN27

CN27

CN21

Open Bio Driver Board

CN23 CN24

Page 2.31

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

BS-10: Solenoid extension cord

Patch – Patch

Patch
CN25

3 + solenoid Blue 3
4 Solenoid ground Red 4

Signal Color Open

CN26

BS-25/LP: LP seat motor cable

Bio Driver Board – Patch cord

Bio Driver

Board

CN6

2 Motor up Red 2
3 Motor down White 3
4 Alarm Green 4
5 Pulses Orange 5
6 Ground Blue 6

Signal Color Open

BS-27/2ALP: LP seat motor cable

LP Driver Board – Patch cord

LP Driver

Board

CN1

1 + motor Black 1
2 - motor Black 2

Signal Color Open

BS-28/2ALP: LP seat motor component cable

LP Driver Board – Patch cord

LP Driver

Board

CN4

1 +5Vdc photocell Black 1
2 Rear switch Red 2
3 Pulses White 3
4 Front switch Green 4
5 Ground photocell Orange 5
6 Ground microswitches Blue 6

The connection cables between cable BS-27/2ALP and the seat motor and between cable BS­28/2ALP and the photocell and the 2 microswitches are not reported because easily described on the
wiring diagram.

Signal Color Open

Page 2.32

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

BS-232: Serial output cable

CPU Board – Serial connector

CPU Board

K15

2 ground Black 5
3 Tx to PC Yellow 2
4 Rx from PC Green 3

Signal Color Serial connector

BS-TLCBR: TGS connector cable

CPU Board – TLCBR

CPU Board

K6

1 + 12 Vdc Red 8
2 ground Black 6
3 Tx to TGS Yellow 2
4 Rx from TGS Green 1

Signal Color TLCBR

BS-30: Signal sensor cable

LP Driver Board – Sensor interface Board

LP Driver Board

CE1 CN2

1 - +12 Vdc Red 1
2 - Alarm White 2

- 2 Ground Black 3

Signal Color Sensor interface

Board

CN2

BS-SAFETY: Sensor-emergency button cable

Sensor Interface Board – Emergency button - Sensor

Sensor Interface

Board

CN1

- Black 1 1
1
2 Signal - Red - 2

The cable BS-SAFETY is the union of the cables BS-38, BS-37, BS-36, BS-35, BS-33BUL and BS­33ABIS.

Signal Color Emergency

button

CN28

Signal +

White 2 -

Sensor

CN30

Page 2.33

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

2.6. SEPARATED BOARD VERSION

2.6.1. TYPE A WIRING DIAGRAM

This diagram is for Abdominal Crunch and Lower Back.

Page 2.34

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

2.6.1.1. Connectors

• Power socket

Name Type of connector Connection

CN11 3 male Faston 6.3x0.8 110/220 Vac line: phase, neutral, earth

• Power switch

Name Type of connector Connection

CN13 2 male Faston 6.3x0.8 110/220 Vac line: phase, neutral
CN14 2 male Faston 6.3x0.8 110/220 Vac line: phase, neutral

• Fuse

Name Type of connector Connection

CN15 2 male Faston 4.8x0.5 110/220 Vac line: phase, neutral
CN16 2 male Faston 4.8x0.5 110/220 Vac line: phase, neutral

• Filter

Name Type of connector Connection

CN17 3 male Faston 6.3x0.8 110/220 Vac line: phase, neutral, earth
CN18 2 male Faston M5 screw slot 110/220 Vac line: phase, neutral, earth

• Selector switch

Name Type of connector Connection

CN19 Contacts to be soldered 110/220 Vac line: phase, neutral

• Power supply (order code 0WA040)

Name Type of connector Connection

CN1 6-pin male PANDUIT 110/220 Vac line: phase, neutral, earth
CN2 6-pin male PANDUIT Low voltage: +12 Vdc, +5 Vdc, ground
CN7 Male Faston for printed circuit 6.3x0.8 Earth contact

• CPU Board (labeled GF961223 - order code 0WQ067)

Name Type of connector Connection

K1 4-pin male AMP MODU I Low voltage: +12 Vdc, +5 Vdc, ground
K3 6-pin male AMP MODU II Serial: RS-232 to FPGA
K4 9x2-pin male AMP MODU II Signals: I/O connection
K5 4x2-pin male AMP MODU II Signals: I/O connection
K6 4-pin male AMP MODU II TLCBR
K15 6-pin male AMP MODU II External serial port

Page 2.35

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

• Solenoid interface board (labeled GF970405 - order code 0WQ080)

Name Type of connector Connection

CN1 4-pin male AMP MODU II Signals: CPU connection
CN2 2-pin female AMP MNL Solenoid
CN3 2-pin terminal board 18 Vac 1A power supply

• Weight stack motor interface board (labeled GF970305 - order code 0WQ119)

Name Type of connector Connection

CN1 6-pin male AMP MODU II Signals: CPU connection
CN2 2-pin terminal board 18 Vac 5A power supply
CN3 6-pin female AMP MNL 24 Vdc motor with reed

• FPGA Board (labeled GF970601 - order code 0WQ069)

Name Type of connector Connection

CN1 8-pin male AMP MODU II Signals: connection with encoder
CN2 6-pin male AMP MODU II RS-232 serial to CPU
CN3 4-pin male AMP MODU I Low voltage: +12 Vdc, +5 Vdc, ground
CN4 4-pin male AMP MODU I Low voltage: +12 Vdc, +5 Vdc, ground

• Patch cords

Name Type of connector Connection

CN21 6-pin open male AMP MNLI Weight stack motor and reed power

supply
CN23 6-pin open male AMP MODU II Encoder signals
CN24 2-pin open male AMP MODU II Zero sensor signal
CN25 2-pin open male AMP MODU II Zero sensor signal
CN26 4-pin open male AMP MODU II Solenoid power supply
CN27 4-pin open male AMP MODU II Solenoid power supply

2.6.1.2. Cables

Power socket

CN11

Faston Earth Yellow–green - Slot
Faston Neutral Blue Faston ­Faston Phase Black Faston -

Page 2.36

BS-11: High-voltage power cable

Power socket – Power switch – Earth node

Signal Color Power switch

CN13

PE

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

BS-12: High-voltage power cable

Power switch – Fuses

Power switch

CN14

Faston Neutral Blue Faston
Faston Phase Black Faston

Signal Color Fuses

CN15

BS-13: High-voltage power cable

Fuses – Filter – Earth node

Fuses
CN16

Faston Neutral Blue Faston ­Faston Phase Black Faston -

- Earth Yellow–

Signal Color CN17

Filter

Faston Slot

green

PE

BS-14: High-voltage power cable

Filter – Power supply – 110/230 Selector switch

Filter
CN18

Slot Ground Yellow 1 -

Faston Neutral Blue

Faston Phase Black

Signal Color Power supply

CN1

4 -

- 1

6 -

- 4

Selector switch

CN19

BS-7/L: Low-voltage power cable

Power supply – FPGA Board

Power supply

CN2 CN7

1 - + 12 V Red 1
3 - + 5 V Orange 4
4 - Ground Gray 3
5 Faston Earth Black 2

The connection between connector CN7 and pin 5 on connector CN2, both on the power supply,
serves to ground the low voltage grounding socket (0 V).

Signal Color FPGA Board

CN3

Page 2.37

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

BS-4: Low voltage cable

FPGA Board – CPU Board

FPGA Board

CN4

1 + 12 Vdc Red 1
2 Ground Black 2
3 Ground Gray 3
4 + 5 Vdc Orange 4

Signal Color CPU Board

K1

BS-6: Signal cable

CPU Board – Low Kit

Solenoid signal cable

CPU Board

K4

17 Enable White 2
15 Status Green 3
12 Ground Gray 4

Signal Color SI board

CN1

Weight stack motor signal cable

CPU Board

K4

3 Motor up Blue 2
5 Motor down Black 3
7 Alarm Gray–pink 4
9 Pulses White–green 5
1 Ground White–yellow 6

Signal Color WSMI board

CN1

FPGA signal cable

CPU Board

K3

3 Tx to CPU White–Blue 4
6 Reset White–brown 5
2 Ground Shield 2

Signal Color FPGA Board

CN2

Zero sensor cable

CPU Board

K5

3 + zero sensor White–black 1
2 Zero sensor ground White–gray 2

Signal Color Zero sensor

CN24

BS-00: Zero sensor extension cable

Patch – Patch

Patch
CN24

1 Signal White 1
2 Ground Black 2

Signal Color Open

CN25

Page 2.38

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

BS-0: Zero contact cable

Zero sensor – Patch

Zero sensor Signal Color Open

Output

Signal White 1
Ground Black 2

BS-2: Weight stack motor cable

Weight stack motor interface board – Patch cord

WSMI board

CN3

1 + motor Red 1
2 - motor Black 2
4 + 12 Vdc White 4
5 Pulses Brown 5
6 Ground Green 6

Signal Color Open

BS-P: Weight stack motor cable

Weight stack motor – Patch

Motor Signal Color Open

+ motor Brown 1

- motor Green 2

Output

+ 12 Vdc Black 4
Pulses White 5
Ground Red 6

BS-9: Weight stack cable

FPGA Board – Solenoid interface board – Patch cord

SI board

board

CN2

CN1

1 - Channel A Green 1 ­2 - Channel B White 2 ­3 - +12 Vdc Red 3 ­4 - Ground Black 4 -

- 1 + solenoid Brown - 3

- 2 Solenoid ground Gray - 4

Signal Color

CN25

CN21

CN21

Open FPGA

CN23 CN26

Page 2.39

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

BS-E: Encoder cable

Encoder – Patch

Encoder Signal Color Open

CN23

Channel A Green 1

Output

Channel B White 2
+12 Vdc Red 3
Ground Black 4

BS-10: Solenoid extension cord

Patch – Patch

Patch
CN26

3 + solenoid Blue 3
4 Solenoid ground Red 4

Signal Color Open

CN27

BS-M: Solenoid cable

Solenoid – Patch

Solenoid Signal Color Open

CN27

Output

+ solenoid White 3
Solenoid ground White 4

BS-232: Serial output cable

CPU Board – Serial connector

CPU Board

K15

2 ground Black 5
3 Tx to PC Yellow 2
4 Rx from PC Green 3

Signal Color Serial connector

BS-TLCBR: TGS connector cable

CPU Board – TLCBR

CPU Board

K6

1 + 12 V Red 8
2 ground Black 6
3 Tx to TGS Yellow 2
4 Rx from TGS Green 1

Signal Color TLCBR

Page 2.40

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

2.6.2. TYPE B WIRING DIAGRAM

This diagram is for Leg Extension not provided with safety device, Leg Curl, Vertical Traction,
Shoulder Press, Chest Press and Rowing Torso.

Page 2.41

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

2.6.2.1. Connectors

• Power socket

Name Type of connector Connection

CN11 3 male Faston 6.3x0.8 110/220 Vac line: phase, neutral, earth

• Power switch

Name Type of connector Connection

CN13 2 male Faston 6.3x0.8 110/220 Vac line: phase, neutral
CN14 2 male Faston 6.3x0.8 110/220 Vac line: phase, neutral

• Fuse

Name Type of connector Connection

CN15 2 male Faston 4.8x0.5 110/220 Vac line: phase, neutral
CN16 2 male Faston 4.8x0.5 110/220 Vac line: phase, neutral

• Filter

Name Type of connector Connection

CN17 3 male Faston 6.3x0.8 110/220 Vac line: phase, neutral, earth
CN18 2 male Faston M5 screw slot 110/220 Vac line: phase, neutral, earth

• Selector switch

Name Type of connector Connection

CN19 Contacts to be soldered 110/220 Vac line: phase, neutral

• Power supply (order code 0WA040)

Name Type of connector Connection

CN1 6-pin male PANDUIT 110/220 Vac line: phase, neutral, earth
CN2 6-pin male PANDUIT Low voltage: +12 Vdc, +5 Vdc, ground
CN7 Male Faston for printed circuit 6.3x0.8 Earth contact

• CPU Board (labeled GF961223 - order code 0WQ067)

Name Type of connector Connection

K1 4-pin male AMP MODU I Low voltage: +12 Vdc, +5 Vdc, ground
K3 6-pin male AMP MODU II Serial: RS-232 to FPGA
K4 9x2-pin male AMP MODU II Signals: I/O connection
K5 4x2-pin male AMP MODU II Signals: I/O connection
K6 4-pin male AMP MODU II TLCBR
K15 6-pin male AMP MODU II External serial port

Page 2.42

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

• Solenoid interface board (labeled GF970405 - order code 0WQ080)

Name Type of connector Connection

CN1 4-pin male AMP MODU II Signals: CPU connection
CN2 2-pin female AMP MNL Solenoid
CN3 2-pin terminal board 18 Vac 1A power supply

• Weight stack motor interface board (labeled GF970305 - order code 0WQ119)

Name Type of connector Connection

CN1 6-pin male AMP MODU II Signals: CPU connection
CN2 2-pin terminal board 18 Vac 5A power supply
CN3 6-pin female AMP MNL 24 Vdc motor with reed

• Seat motor interface board (labeled GF970305 - order code 0WQ081)

Name Type of connector Connection

CN1 6-pin male AMP MODU II Signals: CPU connection
CN2 2-pin terminal board 18 Vac 5A power supply
CN3 6-pin female AMP MNL 24 Vdc motor with reed

• FPGA Board (labeled GF970601 - order code 0WQ069)

Name Type of connector Connection

CN1 8-pin male AMP MODU II Signals: connection with encoder
CN2 6-pin male AMP MODU II RS-232 serial to CPU
CN3 4-pin male AMP MODU I Low voltage: +12 Vdc, +5 Vdc, ground
CN4 4-pin male AMP MODU I Low voltage: +12 Vdc, +5 Vdc, ground

• Patch cords

Name Type of connector Connection

CN21 6-pin open male AMP MNLI Weight stack motor and reed power

supply
CN22 6-pin open male AMP MNLI Seat and reed motor power supply
CN23 6-pin open male AMP MODU II Encoder signals
CN24 2-pin open male AMP MODU II Zero sensor signal
CN25 2-pin open male AMP MODU II Zero sensor signal
CN26 4-pin open male AMP MODU II Solenoid power supply
CN27 4-pin open male AMP MODU II Solenoid power supply

Page 2.43

2.6.2.2. Cables

Power socket

CN11

Faston Earth Yellow–green - Slot
Faston Neutral Blue Faston ­Faston Phase Black Faston -

Power switch

CN14

Faston Neutral Blue Faston
Faston Phase Black Faston

Fuses
CN16

Faston Neutral Blue Faston ­Faston Phase Black Faston -

- Earth Yellow–green Faston Slot

Filter – Power supply – 110/230 Selector switch

Filter
CN18

Slot Ground Yellow 1 -

Faston Neutral Blue

Faston Phase Black

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

BS-11: High-voltage power cable

Power socket – Power switch – Earth node

Signal Color Power switch

CN13

BS-12: High-voltage power cable

Power switch – Fuses

Signal Color Fuses

CN15

BS-13: High-voltage power cable

Fuses – Filter – Earth node

Signal Color CN17

Filter

BS-14: High-voltage power cable

Signal Color Power supply

CN1

4 -

- 1

6 -

- 4

Selector switch

CN19

PE

PE

Page 2.44

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

BS-7/L: Low-voltage power cable

Power supply – FPGA Board

Power supply

CN2 CN7

1 - + 12 V Red 1
3 - + 5 V Orange 4
4 - Ground Gray 3
5 Faston Earth Black 2

The connection between connector CN7 and pin 5 on connector CN2, both on the power supply,
serves to ground the low voltage grounding socket (0 V).

Signal Color FPGA Board

CN3

BS-4: Low voltage cable

FPGA Board – CPU Board

FPGA board

CN4

1 + 12 Vdc Red 1
2 Ground Black 2
3 Ground Gray 3
4 + 5 Vdc Orange 4

Signal Color CPU Board

K1

Page 2.45

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

BS-6: Signal cable

CPU Board – Low Kit

Solenoid signal cable

CPU Board

K4

17 Enable White 2
15 Status Green 3
12 Ground Gray 4

CPU Board

K4

3 Motor up Blue 2
5 Motor down Black 3
7 Alarm Gray–pink 4
9 Pulses White–green 5
1 Ground White–yellow 6

CPU Board

K4

4 Motor up Brown 2
6 Motor down Yellow 3
8 Alarm Orange 4

10 Pulses Red 5

2 Ground Purple 6

CPU Board

K3

3 Tx to CPU White–Blue 4
6 Reset White–brown 5
2 Ground Shield 2

CPU Board

K5

3 + zero sensor White–black 1
2 Zero sensor ground White–gray 2

CAUTION: On the Chest Press only, the BS-4 and BS-6 cables are divided into two

parts - BS-4B and BS-4A, BS-6B and BS-6A - as for the Leg Press. See paragraph 2.6.4.2
for a description of these cables.

Signal Color SI board

CN1

Weight stack motor signal cable

Signal Color WSMI board

CN1

Seat motor signal cable

Signal Color SAMI board

CN1

FPGA signal cable

Signal Color FPGA Board

CN2

Zero sensor cable

Signal Color Zero sensor

CN24

Page 2.46

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

BS-00: Zero sensor extension cable

Patch – Patch

Patch
CN24

1 Signal White 1
2 Ground Black 2

Signal Color Open

BS-0: Zero sensor cable

Zero sensor – Patch

Zero sensor Signal Color Open

Output

Signal White 1
Ground Black 2

BS-2: Weight stack motor cable

Weight stack motor interface board – Patch cord

WSMI board

CN3

1 + motor Red 1
2 - motor Black 2
4 + 12 Vdc White 4
5 Pulses Brown 5
6 Ground Green 6

Signal Color Open

BS-P: Weight stack motor cable

Weight stack motor – Patch

Motor Signal Color Open

+ motor Brown 1

- motor Green 2

Output

+ 12 Vdc Black 4
Pulses White 5
Ground Red 6

CN25

CN25

CN21

CN21

Page 2.47

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

BS-2S: Seat motor cable

Seat motor interface board – Patch cord

SAMI board

CN3

1 + motor Red 1
2 - motor Black 2
5 Pulses Brown 5
6 Ground Green 6

This cable is used only on Vertical Traction, Shoulder Press and Rowing Torso. On Leg Extension,
Leg Curl and Chest Press, the connector CN21 of the motor cable connects directly to connector
CN3 on the seat motor interface board.

Signal Color Open

CN22

BS-S: Seat motor cable

Seat motor – Patch

Motor Signal Color Open

CN22

+ motor White 1

Output

- motor Blue 2
Pulses Red 5
Ground Black 6

BS-9: Weight stack cable

FPGA Board – Solenoid interface board – Patch cord

Open FPGA

CN23 CN26

board

SI board

CN2

Signal Color

CN1

1 - Channel A Green 1 ­2 - Channel B White 2 ­3 - +12 Vdc Red 3 ­4 - Ground Black 4 -

- 1 + solenoid Brown - 3

- 2 Solenoid ground Gray - 4

Page 2.48

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

BS-E: Encoder cable

Encoder – Patch

Encoder Signal Color Open

Channel A Green 1

Output

Channel B White 2
+12 Vdc Red 3
Ground Black 4

BS-10: Solenoid extension cord

Patch – Patch

Patch
CN26

3 + solenoid Blue 3
4 Solenoid ground Red 4

Signal Color Open

BS-M: Solenoid cable

Solenoid – Patch

Solenoid Signal Color Open

Output

+ solenoid White 3
Solenoid ground White 4

BS-232: Serial output cable

CPU Board – Serial connector

CPU Board

K15

2 ground Black 5
3 Tx to PC Yellow 2
4 Rx from PC Green 3

Signal Color Serial connector

BS-TLCBR: TGS connector cable

CPU Board – TLCBR

CPU Board

K6

1 + 12 V Red 8
2 ground Black 6
3 Tx to TGS Yellow 2
4 Rx from TGS Green 1

Signal Color TLCBR

CN23

CN27

CN27

Page 2.49

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

2.6.3. TYPE C WIRING DIAGRAM

This diagram is for Leg Extension provided with safety device.

Page 2.50

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

2.6.3.1. Connectors

• Power socket

Name Type of connector Connection

CN11 3 male Faston 6.3x0.8 110/220 Vac line: phase, neutral, earth

• Power switch

Name Type of connector Connection

CN13 2 male Faston 6.3x0.8 110/220 Vac line: phase, neutral
CN14 2 male Faston 6.3x0.8 110/220 Vac line: phase, neutral

• Fuse

Name Type of connector Connection

CN15 2 male Faston 4.8x0.5 110/220 Vac line: phase, neutral
CN16 2 male Faston 4.8x0.5 110/220 Vac line: phase, neutral

• Filter

Name Type of connector Connection

CN17 3 male Faston 6.3x0.8 110/220 Vac line: phase, neutral, earth
CN18 2 male Faston M5 screw slot 110/220 Vac line: phase, neutral, earth

• Selector switch

Name Type of connector Connection

CN19 Contacts to be soldered 110/220 Vac line: phase, neutral

• Power supply (order code 0WA040)

Name Type of connector Connection

CN1 6-pin male PANDUIT 110/220 Vac line: phase, neutral, earth
CN2 6-pin male PANDUIT Low voltage: +12 Vdc, +5 Vdc, ground
CN7 Male Faston for printed circuit 6.3x0.8 Earth contact

• CPU Board (labeled GF961223 - order code 0WQ067)

Name Type of connector Connection

K1 4-pin male AMP MODU I Low voltage: +12 Vdc, +5 Vdc, ground
K3 6-pin male AMP MODU II Serial: RS-232 to FPGA
K4 9x2-pin male AMP MODU II Signals: I/O connection
K5 4x2-pin male AMP MODU II Signals: I/O connection
K6 4-pin male AMP MODU II TLCBR
K15 6-pin male AMP MODU II External serial port

Page 2.51

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

• Solenoid interface board (labeled GF970405 - order code 0WQ080)

Name Type of connector Connection

CN1 4-pin male AMP MODU II Signals: CPU connection
CN2 2-pin female AMP MNL Solenoid
CN3 2-pin terminal board 18 Vac 1A power supply

• Weight stack motor interface board (labeled GF970305 - order code 0WQ119)

Name Type of connector Connection

CN1 6-pin male AMP MODU II Signals: CPU connection
CN2 2-pin terminal board 18 Vac 5A power supply
CN3 6-pin female AMP MNL 24 Vdc motor with reed

• Seat motor interface board (labeled GF991206 - order code 0WQ00011)

Name Type of connector Connection

CN1 6-pin male AMP MODU II Signals: CPU connection
CN2 2-pin terminal board 18 Vac 5A power supply
CN3 6-pin female AMP MNL 24 Vdc motor with reed
CS1 2-pin open male AMP MINIFIT Safety sensor input signal
CS2 2-pin male AMP MODU II Reset

• FPGA Board (labeled GF970601 - order code 0WQ069)

Name Type of connector Connection

CN1 8-pin male AMP MODU II Signals: connection with encoder
CN2 6-pin male AMP MODU II RS-232 serial to CPU
CN3 4-pin male AMP MODU I Low voltage: +12 Vdc, +5 Vdc, ground
CN4 4-pin male AMP MODU I Low voltage: +12 Vdc, +5 Vdc, ground

• Patch cords

Name Type of connector Connection

CN21 6-pin open male AMP MNLI Weight stack motor and reed power

supply
CN23 6-pin open male AMP MODU II Encoder signals
CN24 2-pin open male AMP MODU II Zero sensor signal
CN25 2-pin open male AMP MODU II Zero sensor signal
CN26 4-pin open male AMP MODU II Solenoid power supply
CN27 4-pin open male AMP MODU II Solenoid power supply
CN28 2-pin open female AMP MINIFIT Safety sensor signal
CN29 2-pin open male AMP MINIFIT Safety sensor signal

Page 2.52

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

2.6.3.2. Cables

BS-11: High-voltage power cable

Power socket – Power switch – Earth node

Power socket

CN11

Faston Earth Yellow–green - Slot
Faston Neutral Blue Faston ­Faston Phase Black Faston -

Signal Color Power switch

BS-12: High-voltage power cable

Power switch – Fuses

Power switch

CN14

Faston Neutral Blue Faston
Faston Phase Black Faston

Signal Color Fuses

BS-13: High-voltage power cable

Fuses – Filter – Earth node

Fuses
CN16

Faston Neutral Blue Faston ­Faston Phase Black Faston -

- Earth Yellow–

Signal Color CN17

BS-14: High-voltage power cable

Filter – Power supply – 110/230 Selector switch

Filter
CN18

Slot Ground Yellow 1 -

Faston Neutral Blue

Faston Phase Black

Signal Color Power supply

PE

CN13

CN15

PE

Filter

Faston Slot

green

Selector switch

CN1

4 -

- 1

6 -

- 4

CN19

Page 2.53

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

BS-7/L: Low-voltage power cable

Power supply – FPGA Board

Power supply

CN2 CN7

1 - + 12 V Red 1
3 - + 5 V Orange 4
4 - Ground Gray 3
5 Faston Earth Black 2

The connection between connector CN7 and pin 5 on connector CN2, both on the power supply,
serves to ground the low voltage grounding socket (0 V).

Signal Color FPGA Board

CN3

BS-4: Low voltage cable

FPGA Board – CPU Board

FPGA board

CN4

1 + 12 Vdc Red 1
2 Ground Black 2
3 Ground Gray 3
4 + 5 Vdc Orange 4

Signal Color CPU Board

K1

Page 2.54

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

BS-6: Signal cable

CPU Board – Low Kit

Solenoid signal cable

CPU Board

Signal Color SI board

K4

17 Enable White 2
15 Status Green 3
12 Ground Gray 4

Weight stack motor signal cable

CPU Board

Signal Color WSMI board

K4

3 Motor up Blue 2
5 Motor down Black 3
7 Alarm Gray–pink 4
9 Pulses White–green 5
1 Ground White–yellow 6

Seat motor signal cable

CPU Board

Signal Color SAMI board

K4

4 Motor up Brown 2
6 Motor down Yellow 3
8 Alarm Orange 4

10 Pulses Red 5

2 Ground Purple 6

FPGA signal cable

CPU Board

Signal Color FPGA Board

K3

3 Tx to CPU White–Blue 4
6 Reset White–brown 5
2 Ground Shield 2

Zero sensor cable

CPU Board

Signal Color Zero sensor

K5

3 + zero sensor White–black 1
2 Zero sensor ground White–gray 2

BS-00: Zero sensor extension cable

Patch – Patch

Patch
CN24

1 Signal White 1
2 Ground Black 2

Signal Color Open

CN1

CN1

CN1

CN2

CN24

CN25

Page 2.55

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

BS-0: Zero sensor cable

Zero sensor – Patch

Zero sensor Signal Color Open

CN25

Output

Signal White 1
Ground Black 2

BS-2: Weight stack motor cable

Weight stack motor interface board – Patch cord

WSMI board

CN3

1 + motor Red 1
2 - motor Black 2
4 + 12 Vdc White 4
5 Pulses Brown 5
6 Ground Green 6

Signal Color Open

CN21

BS-P: Weight stack motor cable

Weight stack motor – Patch

Motor Signal Color Open

CN21

+ motor Brown 1

- motor Green 2

Output

+ 12 Vdc Black 4
Pulses White 5
Ground Red 6

BS-S: Seat motor cable

Seat motor – Seat motor interface board

Motor Signal Color SAMI board

CN3

+ motor White 1

Output

- motor Blue 2
Pulses Red 5
Ground Black 6

Page 2.56

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

BS-9: Weight stack cable

FPGA Board – Solenoid interface board – Patch cord

SI board

board

CN2

CN1

1 - Channel A Green 1 ­2 - Channel B White 2 ­3 - +12 Vdc Red 3 ­4 - Ground Black 4 -

- 1 + solenoid Brown - 3

- 2 Solenoid ground Gray - 4

Signal Color

BS-E: Encoder cable

Encoder – Patch

Encoder Signal Color Open

Channel A Green 1

Output

Channel B White 2
+12 Vdc Red 3
Ground Black 4

BS-10: Solenoid extension cord

Patch – Patch

Patch
CN26

3 + solenoid Blue 3
4 Solenoid ground Red 4

Signal Color Open

BS-M: Solenoid cable

Solenoid – Patch

Solenoid Signal Color Open

Output

+ solenoid White 3
Solenoid ground White 4

Open FPGA

CN23 CN26

CN23

CN27

CN27

Page 2.57

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

BS-232: Serial output cable

CPU Board – Serial connector

CPU Board

K15

2 ground Black 5
3 Tx to PC Yellow 2
4 Rx from PC Green 3

Signal Color Serial connector

BS-TLCBR: TGS connector cable

CPU Board – TLCBR

CPU Board

K6

1 + 12 V Red 8
2 ground Black 6
3 Tx to TGS Yellow 2
4 Rx from TGS Green 1

Signal Color TLCBR

BS-30: Signal sensor cable

Seat motor interface board – Sensor interface Board

SAMI board

CS1 CN2

1 - +12 Vdc Red 1
2 - Alarm White 2

- 2 Ground Black 3

Signal Color Sensor interface

Board

CN2

BS-31: Sensor cable

Sensor Interface Board – Sensor

Sensor Interface

Board

CN1

1 + Signal White 1
2 - Signal Black 2

Signal Color Open

CN29

Page 2.58

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

2.6.4. TYPE D WIRING DIAGRAM

This diagram is for Leg Press.

Page 2.59

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

2.6.4.1. Connectors

• Power socket

Name Type of connector Connection

CN11 3 male Faston 6.3x0.8 110/220 Vac line: phase, neutral, earth

• Power switch

Name Type of connector Connection

CN13 2 male Faston 6.3x0.8 110/220 Vac line: phase, neutral
CN14 2 male Faston 6.3x0.8 110/220 Vac line: phase, neutral

• Fuse

Name Type of connector Connection

CN15 2 male Faston 4.8x0.5 110/220 Vac line: phase, neutral
CN16 2 male Faston 4.8x0.5 110/220 Vac line: phase, neutral

• Filter

Name Type of connector Connection

CN17 3 male Faston 6.3x0.8 110/220 Vac line: phase, neutral, earth
CN18 2 male Faston M5 screw slot 110/220 Vac line: phase, neutral, earth

• Selector switch

Name Type of connector Connection

CN19 Contacts to be soldered 110/220 Vac line: phase, neutral
CN12 Contacts to be soldered 110/220 Vac line: phase, neutral

• Power supply (order code 0WA040)

Name Type of connector Connection

CN1 6-pin male PANDUIT 110/220 Vac line: phase, neutral, earth
CN2 6-pin male PANDUIT Low voltage: +12 Vdc, +5 Vdc, ground
CN7 Male Faston for printed circuit 6.3x0.8 Earth contact

• CPU Board (labeled GF961223 - order code 0WQ067)

Name Type of connector Connection

K1 4-pin male AMP MODU I Low voltage: +12 Vdc, +5 Vdc, ground
K3 6-pin male AMP MODU II Serial: RS-232
K4 9x2-pin male AMP MODU II Signals: I/O connection
K5 4x2-pin male AMP MODU II Signals: I/O connection
K6 4-pin male AMP MODU II TLCBR
K15 6-pin male AMP MODU II External serial port

Page 2.60

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

• Solenoid interface board (labeled GF970405 - order code 0WQ080)

Name Type of connector Connection

CN1 4-pin male AMP MODU II Signals: CPU connection
CN2 2-pin female AMP MNL Solenoid
CN3 2-pin terminal board 18 Vac 1A power supply

• Weight stack motor interface board (labeled GF970305 - order code 0WQ119)

Name Type of connector Connection

CN1 6-pin male AMP MODU II Signals: CPU connection
CN2 2-pin terminal board 18 Vac 5A power supply
CN3 6-pin female AMP MNL 24 Vdc motor with reed

• LP seat motor interface board (labeled GF971127 - order code 0WQ084)

Name Type of connector Connection

CN1 9-pin female AMP MNL 48 Vdc motor, reed and microswitch
CN2 2-pin terminal board 48 Vdc, 6A power supply
CN3 6-pin male AMP MODU II Signals: CPU connection

• FPGA Board (labeled GF970601 - order code 0WQ069)

Name Type of connector Connection

CN1 8-pin male AMP MODU II Signals: connection with encoder
CN2 6-pin male AMP MODU II RS-232 serial
CN3 4-pin male AMP MODU I Low voltage: +12 Vdc, +5 Vdc, ground
CN4 4-pin male AMP MODU I Low voltage: +12 Vdc, +5 Vdc, ground

• Patch cords

Name Type of connector Connection

CN21 6-pin open male AMP MNLI Weight stack motor and reed power

supply
CN23 6-pin open male AMP MODU II Encoder signals
CN25 2-pin open male AMP MODU II Zero sensor signal
CN26 4-pin open male AMP MODU II Solenoid power supply
CN27 4-pin open male AMP MODU II Solenoid power supply
CN28 4-pin open male AMP MODU II Photocell signals
CN29 4-pin open male AMP MODU II Seat limit switch signals
CN30 4-pin open male AMP MODU II Seat limit switch signals
CN31 Male faston 4.8x0.5 Front seat limit switch signals
CN32 Male faston 4.8x0.5 Back seat limit switch signals
CN33 Male faston 6.3x0.8 LP transformer power supply
CN34 6-pin open AMP MODU II connector LP seat control signals

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BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

Name Type of connector Connection

CN35 4-pin open male AMP MODU II Photocell signals
CN36 8x2-pin open male AMP MODU II Signals from CPU to low kit
CN37 6-pin open male AMP MODU II Signals from low kit to encoder and

solenoid
CN38 4-pin open MOLEX MINIFIT Low-voltage FPGA-CPU power supply
CN39 2-pin open AMP MNL LP seat motor power supply

2.6.4.2. Cables

BS-11: High-voltage power cable

Power socket – Power switch – Earth node

Power socket

CN11

Faston Earth Yellow–green - Slot
Faston Neutral Blue Faston ­Faston Phase Black Faston -

Signal Color Power switch

CN13

BS-12: High-voltage power cable

Power switch – Fuses

Power switch

CN14

Faston Neutral Blue Faston
Faston Phase Black Faston

Signal Color Fuses

CN15

BS-13: High-voltage power cable

Fuses – Filter – Earth node

Fuses
CN16

Faston Neutral Blue Faston ­Faston Phase Black Faston -

- Earth Yellow–

Signal Color CN17

Filter

Faston Slot

green

PE

PE

Page 2.62

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

BS-14/LPO: High-voltage power cable

Filter – Power supply – 110/230 Selector switch – Patch cord

Filter
CN18

Slot Ground Yellow 1 - -

Faston Neutral Blue

Faston Phase Black

Signal Color Power supply

CN1

4 - -

- 1 -

- - Faston

6 - -

- 4 -

- - Faston

Selector

switch

CN19

Open

CN33

BS-15/LPO: High-voltage power cable

Patch – 110/230 Selector switch

Patch
CN33

Faston Neutral Blue 4
Faston Phase Black 1

Signal Color Selector switch

CN12

BS-7/L: Low-voltage power cable

Power supply – FPGA Board

Power supply

CN2 CN7

1 - + 12 V Red 1
3 - + 5 V Orange 4
4 - Ground Gray 3
5 Faston Earth Black 2

The connection between connector CN7 and pin 5 on connector CN2, both on the power supply,
serves to ground the low voltage grounding socket (0 V).

Signal Color FPGA Board

CN3

BS-4A: Low voltage cable

FPGA Board– Patch cord

FPGA board

CN4

1 + 12 Vdc Red 1
2 Ground Black 2
3 Ground Gray 3
4 + 5 Vdc Orange 4

Signal Color Open

CN38

Page 2.63

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

BS-4B: Low voltage cable

Patch cord – CPU Board

Patch
CN38

1 + 12 Vdc Red 1
2 Ground Black 2
3 Ground Gray 3
4 + 5 Vdc Orange 4

Signal Color CPU Board

K1

BS-6B: Signal cable

CPU Board – Patch cord

CPU Board

K4

17 Enable White 12
15 Status Green 10
12 Ground Gray 8

3 Motor up Blue 11
5 Motor down Black 13
7 Alarm Gray–pink 15
9 Pulses White–green 16
1 Ground White–yellow 14

4 Motor up Brown 1
6 Motor down Yellow 3
8 Alarm Orange 5

10 Pulses Red 7

2 Ground Purple 9

CPU Board

K3

3 Tx to CPU White–Blue 4
6 Reset White–brown 2
2 Ground Shield 6

CPU Board

K5

3 + zero sensor White–black 1
2 Zero sensor ground White–gray 2

Signal Color Open

CN36

Solenoid signal cable

Weight stack motor signal cable

Seat motor signal cable

FPGA signal cable

Signal Color Open

CN36

Zero sensor cable

Signal Color Zero sensor

CN25

Page 2.64

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

BS-6A: Signal cable

Patch cord – Low kit

Solenoid signal cable

Patch

Signal Color SI board

CN36

12 Enable White 2
10 Status Green 3

8 Ground Gray 4

Weight stack motor signal cable

Patch

Signal Color WSMI board

CN36

11 Motor up Blue 2
13 Motor down Black 3
15 Alarm Gray–pink 4
16 Pulses White–green 5
14 Ground White–yellow 6

Seat motor signal cable

Patch

Signal Color Open

CN36

1 Motor up Brown 2
3 Motor down Yellow 3
5 Alarm Orange 4
7 Pulses Red 5
9 Ground Purple 6

FPGA signal cable

Patch

Signal Color FPGA Board

CN36

4 Tx to CPU White–Blue 4
2 Reset White–brown 5
6 Ground Shield 2

BS-0: Zero sensor cable

Zero sensor – Patch

Zero sensor Signal Color Open

Output

Signal White 1
Ground Black 2

CN1

CN1

CN34

CN2

CN25

Page 2.65

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

BS-2: Weight stack motor cable

Weight stack motor interface board – Patch cord

WSMI board

CN3

1 + motor Red 1
2 - motor Black 2
4 + 12 Vdc White 4
5 Pulses Brown 5
6 Ground Green 6

Signal Color Open

CN21

BS-P: Weight stack motor cable

Weight stack motor – Patch

Motor Signal Color Open

CN21

+ motor Brown 1

- motor Green 2

Output

+ 12 Vdc Black 4
Pulses White 5
Ground Red 6

BS-9A: Weight stack cable

FPGA Board – Solenoid interface board – Patch cord

FPGA

board

CN1

1 - Channel A Green 1
2 - Channel B White 2
3 - +12 Vdc Red 3
4 - Ground Black 4

- 1 + solenoid Brown 5

- 2 Solenoid ground Gray 6

SI board

CN2

Signal Color Open

CN37

Page 2.66

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

BS-9B: Weight stack cable

Patch cord – Patch cord

Signal Color

CN37

1 Channel A Green 1 ­2 Channel B White 2 ­3 +12 Vdc Red 3 ­4 Ground Black 4 ­5 + solenoid Brown - 3
6 Solenoid ground Gray - 4

BS-E: Encoder cable

Encoder – Patch

Encoder Signal Color Open

Channel A Green 1

Output

Channel B White 2
+12 Vdc Red 3
Ground Black 4

BS-10: Solenoid extension cord

Patch – Patch

Patch
CN26

3 + solenoid Blue 3
4 Solenoid ground Red 4

Signal Color Open

BS-M: Solenoid cable

Solenoid – Patch

Solenoid Signal Color Open

Output

+ solenoid White 3
Solenoid ground White 4

Open Patch

CN23 CN26

CN23

CN27

CN27

Page 2.67

LP SAMI Board

CN3

Board

CN1

1 + motor Brown - - 1
2 - motor Blue - - 2
4 +5 Vdc White 2 - ­5 Pulses Blue 3 - ­6 Ground Red 4 - ­7 Rear limit switch Orange - 2 ­8 Front limit switch Yellow - 3 ­9 Ground Black - 4 -

Patch
CN29

Patch
CN30

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

BS-25/LPO: LP seat motor cable

LP SAMI Board – Patch cord

Signal Color Open

CN34

2 Motor up Brown 2
3 Motor down Yellow 3
4 Alarm Orange 4
5 Pulses Red 5
6 Ground Purple 6

BS-20/LPO: LP seat motor extension cable

LP SAMI Board – Patch cord

Signal Color

CN28 CN29 CN39

Open LP SAMI

BS-10/LPO: LP seat motor limit switch extension cable

Patch – Patch

Signal Color Open

CN30

2 Rear limit switch White 2
3 Front limit switch Blue 3
4 Ground Red 4

BS-21/LPO: LP seat motor limit switch cable

Patch cord – Photocell – Limit switch

Signal Color Front limit

switch

CN31

2 Rear limit switch Orange - Faston
3 Front limit switch Yellow Faston ­4 Ground Black Faston Faston

Rear limit

switch

CN32

Page 2.68

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

BS-22/LPO: LP seat motor photocell extension cable

Patch – Patch

Patch
CN28

2 + 5 Vdc White 1
3 Pulses Blue 2
4 Ground Red 4

Signal Color Open

BS-S/LPO: LP seat motor cable

LP seat motor – Patch

Motor Signal Color Open

Output

+ motor Brown 1

- motor Blue 2

BS-F/LPO: LP seat motor photocell cable

LP seat motor photocell – Patch

Motor Signal Color Open

+ 5 Vdc White 1

Output

Pulses Blue 2
Ground Red 4

BS-232: Serial output cable

CPU Board – Serial connector

CPU Board

K15

2 ground Black 5
3 Tx to PC Yellow 2
4 Rx from PC Green 3

Signal Color Serial connector

BS-TLCBR: TGS connector cable

CPU Board – TLCBR

CPU Board

K6

1 + 12 V Red 8
2 ground Black 6
3 Tx to TGS Yellow 2
4 Rx from TGS Green 1

Signal Color TLCBR

CN35

CN39

CN35

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Page 2.70

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

3. OPERATING PRINCIPLE

3.1. BLOCK DIAGRAM

The figure below shows the block diagram for the machine:

Page 3.1

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

3.1.1. POWER ENTRY

This is the entry socket for the machine power supply. It has both an input and output so that up to a
maximum of 3-4 machines may be connected in series. It is located under the floor panels of the
machine, which must be removed to access the power entry.

3.1.2. POWER SWITCH

This is a 2-position (ON and OFF) switch to start the machine. It is housed on a plate together with
the fuse holders, located:

• On Abdominal Crunch, Lower Back, Leg Extension and Leg Curl, under the seat at the back of

the machine;

• On Vertical Traction, Shoulder Press, Chest Press and Rowing Torso, under the seat on the

right-hand side of the machine;

• On Leg Press, next to the weight stack inside the machine.

3.1.3. FUSES

Two fuses are installed to protect both the phase and neutral. Their size depends on the type of
machine, as described in paragraph 2.2. . They are housed on a plate together with the power switch.

3.1.4. FILTER

This is used to reduce conducted disturbance on the line. The filter used is model FN 660,
manufactured by SCHAFFNER. It is attached to the outside of the low kit electrical box.

3.1.5. VOLTAGE SELECTOR BOARD

This is a board which, when used together with a transformer having 2 primary 110-Vac circuits,
ensures the correct power supply to the transformer when powered at either 110 Vac or 230 Vac. It
is able to automatically detect the line voltage type and to switching a relay contact in order to
change the connection of the 2 primary circuits on the standard transformer from serial (for 230-v
power supply) to parallel (for 110-v power supply).

3.1.6. POWER SUPPLY

Receives the incoming line voltage and outputs the direct current (+5 V and +12 V) to power the
display, Bio servo board and encoder. It has a built-in line power supply sensor that allows it to
configure itself to the measured level. It is located inside the low kit electrical box.

3.1.7. TRANSFORMER

Different types of transformers are installed on the machine depending on the type of electrical
diagram:

• Type D diagram with unified board (Leg Press): mounts a transformer with 2 110-Vac

primary circuits and 2 secondary circuits: one at 18Vac/5A and the other at 38Vac/6A. This
transformer powers the Bio Servo board via the 18Vac/5A output, and the LP driver board via
the 38Vac/6A output.

• Other diagrams with unified board: mount a transformer with 2 110-Vac primary circuits,

and 1 secondary circuit at 18 Vac/10A. This transformer powers the Bio Servo board via the
18Vac/10A output.

Page 3.2

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

3.1.8. DISPLAY

This is the “brain” of the machine, and manages all functions according to the instructions received
from the program recorded in the EPROM. The TGS interface (TLCBR and key reader) is built-in
to read exercise data and write exercise feedback on a TGS key, via RS 232 serial port. It controls
all external devices (encoder, weight stack motor, solenoid for the additional weight and, where it is
available, the seat motor) using the Bio servo board to set up the machine as request and shows the
exercise data (weight lifted, speed and power).Upon choosing the exercise, it receives information
from the user via keyboard or via TGS.

If the machine is not used for a time interval specified by the user, it carries out a reset procedure,
during which it tests the efficiency of the external devices connected and sets the motors to their
default values. This reset procedure is also the first to take place each time the machine is switched
on.

It comes complete with buffer battery to provide constant power to a memory containing the
machine configuration data.

3.1.9. BIO SERVO BOARD

It is the board that interfaces the CPU boards to the electronic components.

The board receives continuous power from the power supply, and sends it to the display and
encoder. A green SMD LED, situated in the FPGA section, lights when the board is receiving power
correctly. The board also receives, as input, the 18Vac/10A secondary power from the transformer,
which stabilizes at 24 Vdc for the solenoid, the weight stack and, where available, the seat motor
and 12 Vdc for the internal logic. It is equipped with a 12A fuse to protect it from any short-circuits
on the input voltage.

It has 4 independent sections and each of those manages the electronic components. The 4 sections
are easy identifiable from the position of the connectors to which the electronic components will be
connected:

3.1.9.1. FPGA section

This is the section that receives the encoder signals and processes them. The processed data, that
represents the top plate position, are sent to the CPU via a RS-232 serial connection.

3.1.9.2. Solenoid interface section

This is the section that manages the interface between the CPU board and solenoid. It receives the
solenoid command signal from the CPU board, and based on this signal either supplies or cuts off
working voltage to the solenoid. It generates a status signal as feedback for the command received.

3.1.9.3. Weight stack motor section

This is the section that manages the interface between the CPU board and weight stack motor. It
receives the motor command signal from the CPU board, and based on this signal either supplies or
cuts off working voltage to the motor. It generates an alarm signal if any problems occur on the
motor (overcurrent). It receives the motor encoder signal, which it filters, squares and sends to the
CPU board.

The board uses to power the motor 2 16A relays mounted on a socket.

Page 3.3

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

3.1.9.4. Seat motor section

This is the section that manages the interface between the CPU board and seat motor. It receives the
motor command signal from the CPU board, and based on this signal either supplies or cuts off
working voltage to the motor. It generates an alarm signal if any problems occur on the motor
(overcurrent). It receives the motor encoder signal, which it filters, squares and sends to the CPU
board.

This section is missing on the Abdominal Crunch, Lower Back and Leg Press.

On the Leg Extension it interfaces the safety device signal. In normal condition the safety device is a
NC contact, white it is NA in emergency condition. On the other machines, it is a jumper.

The board uses to power the motor 2 10A relays.

3.1.10. LP DRIVER BOARD

This is the board that manages on the Leg Press the interface between the CPU board, the Bio servo
board and the seat motor.

It receives the motor command signal from the CPU board, and based on this signal either supplies
or cuts off working voltage to the motor. It generates an alarm signal if any problems occur on the
motor:

• surge current;

• short-circuit;

• blocked rotor.

It receives the motor encoder signal, which it filters, squares and sends to the CPU board. It handles
the limit switches in order to prevent that the motor will move in the direction of a pressed limit
switch.

The board is equipped with a programmable chip containing the operating logic, and may be
configured by means of the jumpers:

• Jumper J1

Handles the encoder power supply voltage: if it is in position 1-2, there are 12 Vdc on pin 1 of
connector CN12, while if it is in position 2-3 there are 5 Vdc.

CAUTION: Keep the jumper in position 2-3.

• Jumper J2

To enable limit switch management: management is enabled if open, disabled if closed.

CAUTION: Keep the jumper open at all times.

• Jumper J3

To motor current ripple management: management is enabled if open, disabled if closed.

CAUTION: Keep the jumper open at all times.

Page 3.4

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

It is powered by receiving, as input, a 38Vac/6A secondary power from the specific LP transformer,
which stabilizes (via a 20-A external jumper) at 48 Vdc for the motor and 5 and 12 Vdc for the
internal logic.

There are 3 LEDs on the board:

LED Description

DL1 with the limit switches enabled, it is ON if the front

microswitch is resting, or OFF if the microswitch is pressed

DL2 with the limit switches enabled, it is ON if the rear

microswitch is resting, or OFF if the microswitch is pressed

DL3 It is ON when the board microswitch is properly “functional”

The board uses to power the motor 2 10A relays.

3.1.11. WIRE ENCODER

The wire encoder is located inside the weight stack, attached to a later column, with the wire
fastened to the first plate in the weight stack to measure its position. Moving the weight stack
shortens or lengthens the wire, and the encoder outputs a number of pulses to the Bio servo board in
proportion to the linear movement of the wire.

In order to function properly, it must be powered at 12 Vdc, with a current of at least 100 mA.

3.1.12. SOLENOID

The solenoid is located on the first plate in the weight stack. A pin may be shifted inside it, used to
select the additional weight of 2.5 Kg on all machines, except for the Leg Press, where it is 5 Kg.
When the solenoid is energized, the pin is inside and does not select the additional weight; when it
is not energized, the pin is pushed out by a spring to select the additional weight.

In order to function properly, it must be powered at 24 Vdc that it receives form the Bio servo
board.

3.1.13. WEIGHT STACK MOTOR

The weight stack motor moves the chain, connected to the slide that selects the desired weight. This
is a 24-V, 5-A DC motor complete with:

• an internal reducer (1:79);

• a Hall sensor to measure the rpm (encoder) and supply a square-wave output signal with a duty

cycle of 50%.

In order to function properly, it must be powered at 24 Vdc that it receives form the Bio servo
board.

3.1.14. SEAT MOTOR

This is a linear actuator equipped with:

Page 3.5

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

• 24-V, 5-A DC motor;

• a stem that moves a maximum of 250 mm;

• a reed sensor to measure the rpm (encoder) and supply a square-wave output signal.

Through its stem, the seat motor moves the machine mechanisms that adjust the seat position:

• Forward and back on Leg Extension and Leg Curl;

• Up and down on Vertical Traction, Shoulder Press, Chest Press and Rowing Torso.

This motor is not present on Leg Press, Abdominal Crunch and Lower Back.

In order to function properly, it must be powered at 24 Vdc that it receives form the Bio servo
board.

3.1.15. LP SEAT MOTOR

On Leg Press, the motor and mechanism are different from the other machines: the motor has an
output reducer that powers a gear, which in turn moves the rack and connected seat. The motor is
48Vdc/6A, equipped with dual output shaft, to which the following are connected:

• irreversible 1:100 reducer;

• encoder disc that turns within a photocell, to supply the CPU board with the signal to check the

motor position.

In order to function properly, it must be powered at 48 Vdc that it receives form the LP driver board.

3.1.16. ZERO SENSOR

This is a reed contact that acts as a zero sensor for the weight stack selection system. A magnet is
present on the upper brush of the weight stack selection slide; when it is near this reed, the magnet
causes it to switch status. This makes it possible to define a precise position for the slide, for use as
a reference measure in selecting the plates properly.

3.1.17. SAFETY DEVICE

This device is available on:

• Leg Extension: to prevent the risk of the user’s thigh being crushed between the fixed and

moving parts of the machine seat, an embedded sensor has been installed on the fixed part of the
seat.

• Leg Press: to prevent the risk of the user’s feet being crushed between the machine seat and the

bars, an embedded sensor has been installed on the seat and in series to that an emergency
button has been placed in the column closer to the user.

This sensor consists of a rubber tube containing two conducting strips which make contact when the
tube is pressed. Pressing the tube thus locks the seat and inhibits the seat movement function.

The sensor is connected to the electronics of the machine by means of a sensor interface board.
There are 4 LEDs on this board:

Page 3.6

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

• L1 – red LED: if ON indicates an alarm condition;

• L2 – yellow LED: if ON indicates that the sensor is defective or its connector is open-circuited;

• L3 – green LED: if ON indicates that the circuit board is operating correctly;

• L4 – orange LED: if ON indicates that the sensor is pressed.

During normal operation LED L3 is on. In the case of the following events:

• pressing of the sensor;

• malfunction of the sensor;

• damage to the cable connecting the sensor to the sensor interface board;

• the user presses the emergency button.

the circuit board sends an alarm signal to the Bio servo/LP driver and CPU boards and illuminates
LEDs L1 and L2 or L4. In this condition the seat movement is inhibited until the circuit board is
reset. In order to reset the circuit board:

• turn the machine off and power it back up after a delay of at least 5 seconds.

• short circuit the pins of connector CN3.

WARNING: If the sensor remains pressed, the circuit board will continue to generate

the alarm signal, and the only way to force a recovery from this anomalous condition is
to disconnect cable BS-30 from connector CE1 of the Bio driver board, and then to short
circuit its pins.

Page 3.7

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

3.2. SOLENOID MANAGEMENT

3.2.1. MECHANICS

The additional weight is selected by using a mechanism such as the one schematically illustrated in
the figure below.

Figure 3.2.1

Figure 3.2.2

The solenoid a is located on the first plate in the weight stack. Inside, it contains a pin b that moves
freely in and out, and which is:

• pushed outside the solenoid by the spring c to select the additional weight d when the solenoid

is de-energized (Figure 3.2.1);

• drawn into the solenoid by the magnetic field produced, to deselect the additional weight d,

when the solenoid is energized (Figure 3.2.2).

3.2.2. CONTROLS

To change the selection of the additional weight, the CPU board sends the enable signal to the Bio
servo board. This powers the solenoid properly, which in turn generates an internal field that draws
the pin inside, to avoid selecting the additional weight.

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BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

The Bio servo board can check whether the solenoid is absorbing current (meaning that it is
energized, and thus the pin does not select the additional weight) and send this information to the
CPU board to notify that the check has been successful.

3.2.3. THE SIGNALS INVOLVED

The machine controls selection of the additional weight via the CPU board, the Bio servo board and
the solenoid as shown in the figure below:

CPU board

17-1/K4 15-1/K4

Enable

13-1/CN7 15-1/CN7

Status

Bio servo board

5-6/CN3

S

Solenoid

The following signals come into play:

• Enable signal

This is the signal generated by the CPU (pin 17-1 on connector K4) to enable the solenoid. This
signal enters the Bio servo board (pins 13-1 on connector CN7), and is processed by the latter to
pilot the solenoid with the proper supply voltage.

The control logic states that when the enable signal is high (~ 4 V) the solenoid is powered (24
Vdc) and the pin does not select the additional weight, while when the signal is low (~ 0 V) the
solenoid is not powered (0 Vdc) and the pin selects the additional weight.

The figure below shows the switching of the enable signal to select the additional weight:

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BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

Figure 3.2.3

• Status signal

This is the signal generated by the Bio servo board (pins 15-1 on connector CN7) to notify the
CPU board (pins 15-1 on connector K4) of the solenoid status: if this signal is high (~ 5 V), no
current is circulating in the solenoid; if it is low (~ 0 V), current is circulating in the solenoid.

The figure below shows the switching of the status signal caused by selection of the additional
weight:

Figure 3.2.4

• Voltage on solenoid

This is the signal for the solenoid generated by the solenoid interface board (pins 5-6 on
connector CN3): when it is 24 Vdc the solenoid is powered; when it is 0 Vdc, the solenoid is not
powered.

The figure below shows the switching of the power supply signal caused by selection of the
additional weight:

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BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

Figure 3.2.5

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BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

3.3. WEIGHT STACK MOTOR MANAGEMENT

3.3.1. MECHANICS

Each plate a of the weight stack is fitted with a pin b that is pushed out by a small spring c:

• when the pin is in its external position, the plate hooks onto the cross d (Figure 3.3.1);

• when the pin is in its internal position, the plates are released from the cross d (Figure 3.3.2).

Figure 3.3.1

Figure 3.3.2

By adjusting the position of the selector switches appropriately, it is possible to select the desired
plates, and thus the weight with which to perform the exercise. The additional weight is selected by
using a mechanism such as the one schematically illustrated in the figure below:

Page 3.12